D375A 5 Workshop Manual

GENERAL
01 GENERAL
SPECIFICATION DRAWING .....................................................................................................................
SPECIFICATIONS .....................................................................................................................................
WEIGHT TABLE ........................................................................................................................................
TABLE OF FUEL, COOLANT AND LUBRICANT ......................................................................................
01- 2
01- 4
01-10
01-12
D375A-5
01-1
GENERAL
SPECIFICATION DRAWING
SPECIFICATION DRAWING
Item
Unit
Semi U-tilt dozer

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

+ Multi-shank ripper
U-tilt dozer
+ Multi-shank ripper
Overall
length
mm
10,330
10,695
10,040
10,405
Overall
height
(with ROPS)
mm
4,035
(4,230)
4,035
(4,230)
4,035
(4,230)
4,035
(4,230)
Overall
width
mm
4,695
5,140
4,695
5,140
01-2
D375A-5
GENERAL
SPECIFICATIONS
SPECIFICATIONS
Machine model
D375A-5
Serial number
18001 and up
Machine weight
Bare tractor with semi u-dozer
Ditto with variable multi-shank ripper
49,800
kg
60,340
Ditto with ROPS cab + Air conditioner +
67,060
Seat belt + Perforated side cover + SSC
68,500
Minimum turning radius
4.2
Gradeability
deg.
30
Stability (front, rear, left, right)
deg.
35
1st speed
2nd speed
0 3.8
km/h
0 6.8
3rd speed
0 11.8
1st speed
0 5.1
2nd speed
km/h
3rd speed
0 9.2
0 15.8
Bare tractor
103.16 {1.06}
With semi U-dozer
125.53 {1.28}
140.37 {1.43}
With semi U-dozer + Variable multishank ripper
kPa {kg/cm2}
143.38 {1.46}
Ditto with ROPS cab + air conditioner

+ Seat belt + Perforated side cover +
SSC
Bare tractor
5,770
With semi U-dozer
7,635
With semi U-dozer + Variable multishank ripper
mm
With U dozer + Variable multi-shank
10,040
10,405
ripper
Bare tractor
With semi U-dozer
3,220
mm
With U-dozer
To top of exhaust pipe
To top of air intake duct
01-4
4,695
5,140
mm
4,035
3,429
D375A-5
GENERAL
SPECIFICATIONS
Machine model
D375A-5
Serial number
18001 and up
Track gauge
Length of track on ground
Track shoe width
Minimum ground clearance
mm
Name
SA6D170E-3
Type of engine
Number of cylinders Bore Stroke
Piston displacement
Flywheel horsepower
Max. torque
Max. speed at no load
Min. speed at no load
Min. fuel consumption ratio
Starting motor
Alternator
Battery
Radiator core type
Torque converter
Transmission
2,500
3,840
610
610
4-cycle, water-cooled, in-line vertical type, direct injection type with turbocharger and aftercooler
mm
{cc}
6 170 170
23.15 {23,150}
kw {HP}/rpm
Nm {kgm}/rpm
rpm
rpm
391 {525}/1,800
2,648 {270}/1,300
1,900
720
g/kw.h
{g/HP.h}
209 {156}
24 V, 7.5 kW 2
24 V, 60 A
12 V, 170 Ah 2
Type D
3-element, 1-stage, 1-phase (with lockup clutch)
Planetary gear type, multiple disc clutch type, hydraulic
actuation type, lubricating oil pump force-feeding type,
forward 3-speed, reverse 3-speed
Bevel gear shaft
Spiral bevel gear type, lubricating oil splashing type
Steering clutch
Wet type, multiple disc clutch type, spring-boosted

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

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

type, lubricating oil splashing type
D375A-5
01-5
GENERAL
SPECIFICATIONS
Machine model
D375A-5
Serial number
18001 and up
Suspension
Rigid, balancing beam type
Carrier roller
2 each side
Track roller
7 each side
Track shoe
Assembly type, single grouser, 40 each side,

pitch: 280.0 mm, width: 610 mm
Power train + lubricating oil pump (tandem)
Gear type (BAL 180 + 112)
Scavenging pump (tandem)
Gear type (BAR 63 + 277)
PPC charge pump
Gear type (SAR(1) 022)
(work equipment pump and tandem)

Maximum pressure
MPa {kg/cm2}
Type
20.6 {210}
Gear type, double type (SAR(4) 140 + (3) 071)
Delivery
/min
405
(at engine speed of 1,800 rpm)

Type
For blade lift
Single pilot spool type, with demand spool
For blade tilt, ripper LO
Triple pilot spool type
For ripper HI
Double pilot spool type
Type
Double acting piston type

Cylinder bore
150
Piston rod outside diameter

Piston stroke
90
mm
Max. distance between pins
2,650
Min. distance between pins
1,145
225
Cylinder bore
Piston stroke
01-6
1,505
110
mm
240
1,668
1,428
D375A-5
GENERAL
SPECIFICATIONS
Machine model
D375A-5
Serial number
18001 and up
Cylinder bore
Left cylinder: 225, Right cylinder: 250
110
(both right and left)

Piston stroke
185
mm
1,665

1,480

Cylinder bore
225
110

Piston stroke
mm
495
1,855
1,360
200
Cylinder bore
110

Piston stroke
mm
550
1,800
1,250
Control valve assembly type
Hydraulic tank
(external installation type)

Hydraulic semi U-tilt dozer,
Type
Hydraulic U-tilt dozer
Blade support method

Max. lifting height
Brace type
mm
1,660
mm
715
Max. tilt
mm
1,065
Blade cutting angle variation
deg.
(from ground level)

Max. lowering depth
(from ground level)
D375A-5
Blade capacity
24.0 <SAE18.5>
Blade width
mm
4,695
Blade height
mm
2,265
Blade cutting angle
deg.
55
01-7
GENERAL
SPECIFICATIONS
Machine model
D375A-5
Serial number
18001 and up
Max. lifting height
mm
1,660
mm
715
Max. tilt
mm
1,165
Blade cutting angle variation
(from ground level)

Max. lowering depth
(from ground level)
deg.
Blade capacity
m3
26.3 <SAE22.0>
Blade width
mm
5,140
Blade height
mm
2,265
Blade cutting angle
deg.
55
Max. tilt
mm
1,150
Max. pitch angle
deg.
Blade cutting angle
deg.
Max. tilt
mm
1,260
Max. pitch angle
deg.
Blade cutting angle
deg.
Max. digging depth
mm
1,075
Max. lifting height
mm
1,050
Point digging angle
deg.
45 (Stepless adjustment is possible

between 32.5 and 55.5 deg.)
Max. beam width

Shank position
mm
2,854
Number of
holes
Max. digging depth
mm
1,435
Max. lifting height
mm
1,060
Point digging angle
deg.
45 (Stepless adjustment is possible

between 32.5 and 55.5 deg.)
Max. beam width

Shank position
mm
1,367
Number of
holes
01-8
D375A-5
GENERAL
WEIGHT TABLE
WEIGHT TABLE
k This weight table is for reference in handling or transporting components.
Unit: kg
Machine model
D375A-5
Serial number
18001 and up
Engine and damper assemblies
3,080
Engine assembly
2,850
Damper assembly
Engine mounting parts
Radiator assembly
Oil cooler assembly
Fuel tank assembly (when full)
160
70
390
100
478 (1,368)
Power train unit

Torque converter, PTO assembly
Transmission assembly
Transmission valve assembly
Steering clutch and brake assembly
Steering valve assembly
795
1,000
13
1,712
13
Final drive assembly
2,200 2
Main frame assembly
5,541
Track group assembly (each side)
7,259
Track frame
2,038
Idler assembly
478
Track roller assembly (single flange 1)
150 4
Track roller assembly (double flange 1)
160 3
Carrier roller assembly (each)

First bogie and track roller assembly
Second fourth bogies and track roller assembly
Track shoe assembly
Pivot shaft
71 2
258
717 3
4,200 2
210 2
Equalizer assembly
490
Hydraulic tank assembly
370
Work equipment valve (blade lift)
57
Work equipment valve (blade tilt, ripper LO)
36
01-10
D375A-5
GENERAL
WEIGHT TABLE
Unit: kg
Machine model
D375A-5
Serial number
18001 and up
Semi U-dozer assembly
10,540
Blade
4,870
Straight frame (left)
1,130
Straight frame (right)
1,130
Tilt cylinder assembly

Variable multi-shank ripper assembly
295
6,720
Shank assembly
470 3
Ripper lift cylinder assembly
345 2
Ripper tilt cylinder assembly
265 2
Variable giant ripper assembly
5,470
Shank assembly
650 1
Ripper lift cylinder assembly
345 2
Ripper tilt cylinder assembly
265 2
Radiator guard assembly (including cylinder yoke)
2,100
Radiator guard
1,332
Blade lift cylinder assembly

Mask
268 2
50
Engine underguard
285
Power train underguard (front)
275
Power train underguard (rear)
250
Hood
145
Fender (left)
315
Fender (right)
355
ROPS assembly
766
Floor frame assembly
591
Cab assembly
415
Operator seat assembly
D375A-5
64
01-11
GENERAL
TABLE OF FUEL, COOLANT AND LUBRICANT
TABLE OF FUEL, COOLANT AND LUBRICANT
Ambient temperature
Refilling position
Kind of oil
30
20
10
10
20
30
Specified
Refilled
oil amount oil amount
40C
()
()
SAE 30CD
SAE 10WCD
Engine oil pan
68
55.5
275
150
2.1
2.1
61
61
18
18
280
120
0.95 1.05
0.95 1.05
1.40 1.50
1.40 1.50
0.70 0.80
0.70 0.80
0.095
0.115
0.095
0.115
1,050
165
SAE 10W-30CD
SAE 15W-40CD
Power train oil pan

including torque converter, transmission and bevel gear case
SAE 30CD
Engine oil
SAE 10WCD
Damper case
Final drive case (each side)
SAE 30CD
Pivot shaft case (each side)
SAE 10WCD
SAE 10W-30CD
Hydraulic oil
SAE 15W-40CD
Idler (each)
Track roller (each)
Gear oil
GO 140
Carrier roller (each)

Bogie cartridge pin (each)
ASTM D975 No. 2
Fuel tank
Diesel fuel
ASTM D975
No. 1
Cooling system
01-12
4
Coolant
Komatsu genuine super coolant (AF-NAC added)
D375A-5
STRUCTURE, FUNCTION AND

MAINTENANCE STANDARD
10 STRUCTURE, FUNCTION AND

POWER TRAIN ........................................................................................................................................
OVERALL DRAWING OF POWER TRAIN UNIT ....................................................................................
POWER TRAIN HYDRAULIC PIPING DRAWING ..................................................................................
DAMPER, UNIVERSAL JOINT ................................................................................................................
TORQUE CONVERTER, PTO .................................................................................................................
TORQUE CONVERTER VALVE ..............................................................................................................
SCAVENGING PUMP .............................................................................................................................
TRANSMISSION CONTROL ...................................................................................................................
TRANSMISSION ......................................................................................................................................
TRANSMISSION ECMV ..........................................................................................................................
TRANSMISSION LUBRICATION RELIEF VALVE ..................................................................................
POWER TRAIN PUMP + LUBRICATION PUMP ....................................................................................
STEERING, BRAKE CONTROL .............................................................................................................
TRANSFER, BEVEL GEAR SHAFT, STEERING ....................................................................................
STEERING ECMV ...................................................................................................................................
STEERING CLUTCH, STEERING BRAKE ECMV ..................................................................................
PARKING BRAKE VALVE .......................................................................................................................
SUDDEN STOPS PREVENTION VALVE ................................................................................................
FINAL DRIVE ..........................................................................................................................................
TRACK FRAME .......................................................................................................................................
RECOIL SPRING ....................................................................................................................................
IDLER ......................................................................................................................................................
TRACK ROLLER ......................................................................................................................................
CARRIER ROLLER .................................................................................................................................
TRACK ROLLER BOGIE .........................................................................................................................
TRACK SHOE ..........................................................................................................................................
MAIN FRAME ..........................................................................................................................................
SUSPENSION .........................................................................................................................................
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM ...........................................................................
PPC CONTROL PIPING DIAGRAM ........................................................................................................
WORK EQUIPMENT CONTROL ............................................................................................................
HYDRAULIC TANK .................................................................................................................................
PPC CHARGE VALVE ............................................................................................................................
ACCUMULATOR .....................................................................................................................................
PPC LOCK VALVE ..................................................................................................................................
PPC VALVE .............................................................................................................................................
WORK EQUIPMENT CYLINDER ............................................................................................................
PISTON VALVE .......................................................................................................................................
QUICK DROP VALVE .............................................................................................................................
PIN PULLER SWITCH .............................................................................................................................
PIN PULLER SOLENOID VALVE ............................................................................................................
BLADE CONTROL KNOB .......................................................................................................................
PITCH, DUAL TILT SOLENOID VALVE ..................................................................................................
D375A-5
10- 4
10- 6
10- 8
10- 10
10- 12
10- 20
10- 31
10- 32
10- 34
10- 46
10- 52
10- 53
10- 54
10- 57
10- 64
10- 68
10- 75
10- 76
10- 77
10- 82
10- 84
10- 86
10- 88
10- 89
10- 90
10- 92
10- 94
10- 96
10- 99
10-103
10-104
10-106
10-108
10-111
10-112
10-114
10-124
10-127
10-128
10-130
10-131
10-133
10-134
10-1

WORK EQUIPMENT + PPC CHARGE PUMP ........................................................................................ 10-136

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

POWER TRAIN
POWER TRAIN
Outline
The power generated by engine (1) has its torsional vibration dampened by damper (2), and
then passes through universal joint (3), and it
transmitted to torque converter (7).
The power from the engine is transmitted
through oil by torque converter (7) to the input
shaft (turbine shaft) of transmission (8) in accordance with the change in the load.
There is a lock-up clutch assembled to the
torque converter, and when the rotating speed
beyond the torque converter becomes higher,
the lock-up clutch is engaged. When this happens, the drive case and turbine form one unit,
so the power from the engine is transmitted directly to the transmission input shaft.
Transmission (8) uses a combination of a planetary gear system and hydraulic equipment to reduce the speed and shift the gears (forward: 3
gears, reverse: 3 gears). It connects two sets of
clutches selected with the gear shift lever according to the change in the load, and transmits
the power from the transmission to transfer (14)
from the output shaft.
The power entering transfer (14) has its speed
reduced. Its speed is further reduced by the bev-
10-4
el pinion and bevel gear of the bevel gear shaft,

and it is then divided at right angles to the left
and right and transmitted to the respective steering clutches (9).
The power transmitted from the bevel gear shaft
to the final drive is used to steer the machine by
engaging on disengaging steering clutch (9).
The steering lever is operated to disengage the
steering clutch on the side to which the machine
is to be steered in order to change the direction
of travel. The size of the turning radius is controlled by steering brake (10) installed to the outside of the steering clutch.
Steering brake (10) uses the same disc system
that is used for the steering clutch.
The power output from the steering clutch enters
final drive (11), where it is reduced, and rotates
sprocket (12).
Final drive (15) is a double reduction type consisting of a single stage spur gear and single
stage planetary gear system.
It rotates the sprocket to drive track shoe (13)
and move the machine.
D375A-5

1.
2.
3.
4.
Engine (SA6D170E-3)
Damper
Universal joint
Power train pump
(BAL 180 + 112)
5. PTO
D375A-5
POWER TRAIN
6. Hydraulic pump
(SAR(4)140 + (3)071 + (1)022)
7. Torque converter
8. Transmission
9. Steering clutch
10. Steering brake
11.
12.
13.
14.
15.
Final drive
Sprocket
Track shoe
Transfer
Scavenging pump
(BAR 63 + 277)
10-5

OVERALL DRAWING OF POWER TRAIN UNIT
10-6
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
PTO
Torque converter
Torque converter valve
Transmission control valve
Transmission
Steering clutch, brake
Steering control valve
Power train pump (BAL 180 + 112)
Transmission lubrication oil filter
Power train oil filter
Power train oil strainer
Scavenging pump (BAR 63 + 277)
Power train oil tank
D375A-5
Function
The power train unit can be broadly divided into

the torque converter and transmission unit and
the steering unit.
Therefore, after the power train is removed as a
unit, it can be divided into the torque converter
and transmission unit and the steering unit.
The steering unit consists of the transfer, bevel
gear shaft, steering clutches, and steering
brakes.
10-7

POWER TRAIN HYDRAULIC PIPING DRAWING
POWER TRAIN HYDRAULIC PIPING DRAWING
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Oil cooler
Power train oil filter
Transmission lubrication oil filter
Centralized pressure detection port
Torque converter valve
Transmission control valve (ECMV)
Steering control valve (ECMV)
Power train oil tank
Power train oil strainer
Power train pump (BAL 180 + 112)
Scavenging pump (BAR 63 + 277)
A.
B.
C.
D.
E.
F.
G.
H.
J.
K.
L.
M.
N.
P.
10-8
Torque converter lock-up pressure pick-up port

Torque converter stator clutch pressure pick-up port
Left-steering clutch operating pressure pick-up port
Left-steering brake operation pressure pick-up port
Transmission 2nd clutch operating pressure pick-up
port
Transmission R clutch operating pressure pick-up port
Transmission 3rd clutch operating pressure pick-up
port
Transmission F clutch operating pressure pick-up port
Right-steering brake operating pressure pick-up port
Right-steering clutch operating pressure pick-up port
Transmission 1st clutch operating pressure pick-up
port
Transmission main relief pressure pick-up port
Torque converter regulator pressure pick-up port
Torque converter relief pressure pick-up port
D375A-5

DAMPER, UNIVERSAL JOINT
10-10
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Outline
Outer body
Engine flywheel
Output shaft
Coupling
Universal joint
Flange
Rubber coupling
Cover
Breather
Oil level gauge tube
The damper protects the power train (such as

the torque converter and transmission) by buffering torsional vibrations resulting from fluctuations in engine torque or impact torque resulting
from sudden acceleration or heavy-duty operation.
The rubber coupling on the damper efficiently
absorbs vibrations by rubber materials internal
damping effects and deformation as well as frictional damping effects of the rubber material.
This arrangement also helps reducing number of
components used.
Operation
No.
Check item
Clearance between the flywheel

11
housing and cover
12
Clearance between the flywheel

and damper
Outside diameter of the couplings

13
oil seal contact surface
14
Outside diameter of the output

shafts oil seal contact surface
15
Dimension between the bearing

and holder
D375A-5
Motive power of engine is transmitted to the flywheel (2) and outer body (1) through the rubber
coupling (8). After absorption of torsional vibrations of the engine by the rubber coupling, power
is then transmitted to the coupling (4) via the output shaft (3).
Then, power is further transmitted from the coupling to the universal joint (5) up to the torque
converter input shaft.
Unit: mm
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
647.7
+0.024
+0.105
+0.080
0
0.024
0.185
0.2
546.0
0.022
0.092
+0.110
0
0.022
0.202
0.25
Standard size
Repair limit
0
110 0.035
109.9
0
110 0.035
109.9
48 0.1
47.7
Replace
10-11

TORQUE CONVERTER, PTO
1. Coupling
2. Seal cage
3. Input shaft
[PTO drive gear (61 teeth)]
4. Front housing
5. Idler gear (77 teeth)
6. Idler gear shaft
7. Clutch housing
8. Drive case
9. Turbine
10. Rear housing
11. Stator
12. Pump
13. Stator shaft
10-12
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Bearing cage
Retainer
Shaft
Transmission input shaft
Stator shaft boss
Stator clutch housing
Return spring
Stator clutch plate
Stator clutch disc
Stator clutch piston
Turbine boss
Lock-up clutch disc
Lock-up clutch plate
Lock-up clutch piston
28. Scavenging pump gear

(63 teeth)
29. Seal seat
30. Spacer
31. Cover
32. Hydraulic pump gear (57 teeth)
33. Power train pump gear
(57 teeth)
34. Cover
35. Cover
A. Hydraulic pump mount
B. Power train pump mount
C. Scavenging pump mount
D375A-5

D375A-5
10-13

10-14
D375A-5

Unit: mm
No.
1
Check item
Outside diameter of coupling oil
seal contact surface
Criteria
Remedy
Standard size
Tolerance
Repair limit
125
0
0.063
124.8
Inside diameter of retainer seal

ring contact surface
190
+0.046
0
190.5
Inside diameter of sleeve seal ring

contact surface
110
+0.035
0
110.2
Backlash between PTO drive gear

and scavenging pump drive gear
Backlash between PTO drive gear

and driven gear
Wear of stator shaft seal ring
Standard clearance
Clearance limit
0.250 0.420
0.204 0.516
Standard size
Repair limit
Width: 5.95
Height: 6.50
Width: 5.35
Height: 5.85
Thickness of disk
5.4
5.0
Thickness of plate
5.0
4.5
Thickness of
overall assembly
15.8
14.5
Thickness of disk
5.4
5.1
Thickness of plate
5.0
4.5
15.8
14.7
Thickness of
overall assembly
Standard size
9
Stator clutch spring
D375A-5
Repair hard
chrome plating or
replace
Replace
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
54.1
37.0
125.5 N
{12.8 kg}
52.5
106.9 N
{10.9 kg}
10-15

Outline
Structure
The torque converter design employs 3-element,

1-stage and 3-phase arrangement. It is, structurally, united with the transmission.
In order to reduce consumption of fuel and engine horsepower as well as increase operating
performance, the torque converter incorporates
the wet type/double plate clutch type torque converter lock-up device plus the stator clutch device.
In continuous light load dozing operations or leveling operation, motive power of the engine can
be more effectively utilized when it is transmitted
directly to the transmissions input shaft. It is why
the hydraulically operated lock-up clutch is incorporated into the converter. When the torque converter is locked up (when the pump and turbine
are united), oil supply from the converter relief
valve is not stopped. Thus, the oil conducted out
of the pump - turbine used to be provided with
unnecessary directivity by the stator, resulting in
resisting against the pump and turbine rotation
(stirring of oil). In order to return the oil discharged from the pump - turbine to the pump
with smaller resistance, the stator clutch has
been installed to enable drag turning of the stator
accompanying the rotation of the pump and turbine as the torque converter is locked up.
Following describes the lock-up mode of the
torque converter and the conditions to be met by
the torque converter mode.
Lock-up range
Torque converter output shaft rotation speed:
1,260 rpm minimum
Torque converter range
Torque converter output shaft rotation speed:
1,230 rpm maximum
The torque converter mode is maintained as
long as gear speed change from the transmission is taking place.
10-16
The pump (12) is united with the coupling (1),

shaft (3), clutch housing (7) and drive case (8). It
is rotated by motive power from the engine.
The turbine (9) is united with the turbine boss
(24) and transmission input shaft (turbine shaft)
(17). It is rotated by oil from the pump.
The stator (l1) is united with the stator shaft (13)
and stator boss (18). It is fixed to the rear housing (10) via the stator clutch device.
The lock-up clutch device is consisted of the
clutch plate (26) engaged with the drive case (8),
the clutch disk (25) engaged with the turbine
boss (24), and the clutch piston (27) that slides
in the housing (7) united with the drive case.
The stator clutch device is consisted of the clutch
disk (22) engaged with the boss (18) (the boss is
connected to the stator shaft (13) via the spline),
the clutch plate (21) being secured to the clutch
housing (19) and rear housing (10) with the pin,
and the clutch piston (23) that slides in the rear
housing.
PTO device is consisted of the input shaft (3),
idler gear (5), scavenging pump drive gear (28),
work equipment pump drive gear (32) and power
train pump drive gear (33).
D375A-5

Path of transmission of motive force

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

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

Flow of oil
Oil set to within 0.90 MPa {9 kg/cm2} by

the torque converter relief valve flows
from port A, passes through the oil hole
inside rear housing (10), and enters
pump (12).
The pump is always being rotated by the
power from the engine, so the oil entering the pump is given centrifugal force,
and enters turbine (9). The turbine is rotated by the centrifugal force of the oil.
The turbine forms one unit with transmission input shaft (17), so the motive
force received by the turbine is transmitted to the transmission.
The oil leaving the turbine is sent to stator (11) and enters the pump again, but
some of the oil passes from the stator
through port B and is sent to the oil cooler.
10-18
D375A-5

TORQUE CONVERTER VALVE
1. Valve body
2. Torque converter relief
valve
3. Valve spring
4. Valve spring
5. Main relieve valve
6. Cover
7. Piston
8. Piston ring
9. Piston
10. Stator clutch modulating valve
11. Piston
12. Piston ring (small)
13. Piston
10-20
14. Lock application clutch

modulating valve
15. Cover
16. Piston
17. Piston ring (small)
18. Piston
19. Valve spring (outside)
20. Valve spring (inside)
21. Stopper
22. Load piston
23. Cover
24. Valve spring (outside)
25. Cover
26. Valve spring
27. Valve body
28. Lock-up selector valve

29. Piston
30. Cover
Lock-up solenoid valve
assembly
31. Cap
32. Coil
33. Valve
34. Ball
35. Valve
36. Base
37. Shaft
38. Case
39. Plunger
P.
Status clutch pressure pick-up port

P1. Torque converter relief pressure pick-up
port
P3. Lock-up clutch pressure pick-up port
P8. Main relief pressure
pick-up port
P10. Torque converter regulator pressure pickup port
D375A-5

Outline
The torque converter valves are provided at the

top of the torque converter housing. They are
consisted of the following six types of the valves.
1. Main relief valve

The main relief valve (5) regulates pressure on
the hydraulic circuits of the transmission, steering clutch, lock-up clutch of the brake and torque
converter, and stator clutch to 2.55 to 2.75 MPa
{26.0 28.0 kg/cm2}.
2. Torque converter relief valve
The torque converter relief valve (2) regulates
the pressure at the entrance of the torque converter to 0.88 MPa {9.0 kg/cm2} in order to protect it from abnormally high pressure.
3. Converter lock-up valve
The lock-up selector valve (24) are used to turn
on or off the lock-up clutch and the stator clutch.
D375A-5
4. Torque converter lock-up solenoid valve

As the electric signal from the controller is received, the solenoid valve switches the pilot
pressure to the lock-up selector valve (28) in order to turn on or off the two clutches via the selector valve (28).
The modulating valve (10) regulates the clutch
pressure to 2.65 MPa {27.0 kg/cm2} in order to
protect the stator clutch from abnormally high
temperature. It is also used to increase pressure
of the oil from the lock-up selector valve (28) to
the specified level.
6. Lock-up clutch modulating valve
Function of the modulating valve (14) is similar to
that of the stator clutch modulating valve (10).
This valve is used to regulate the clutch pressure
to 1.3 MPa {13 kg/cm2}.
10-21

10-22
D375A-5

Unit: mm
No.
Check item
Clearance between main relief

valve and valve body
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
+0.016
0
0.035 0.061
0.08
Shaft
Hole
40
0.035
0.045
Clearance between torque

converter relief valve and valve
40
0.035
0.045
+0.016
0
0.035 0.061
0.08
Clearance between stator clutch

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

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

valve and valve body
25
0.020
0.030
+0.013
0
0.020 0.043
0.06
Standard size
6
Main relief valve spring
Repair limit
Replace
Free length
Installed
length
Installed
load
Free length
Installed
load
120.3
103
1,339.4 N
{136.7 kg}
116.7
1,272.4 N
{129.9 kg}
Torque converter relief valve

spring
116.92
90.8
550.4 N
{56.16 kg}
113.41
523.2 N
{53.35 kg}
Stator clutch modulating valve

spring
103.5
95.2
151.9 N
{15.5 kg}
100.4
144.4 N
{14.7 kg}
Lock-up clutch modulating valve

spring (Outside)
141.4
88.7
158.6 N
{16.18 kg}
137.16
150.7 N
{15.37 kg}
10
Lock-up clutch modulating valve

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

Operation of main relief valve
The oil from the power train pump passes

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

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

Torque Converter Lock-up Control System

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

The lock-up ON/OFF operation is carried out

when the sensor signal conforms to the conditions below. (It is not turned ON during gear shifting.)
1. Conditions for ON (AND circuit)
1) Not during gear shifting (The status that
the clutch is completely engaged):
The transmission controller recognizes
the status.
2) When the right-sided conditions for the
ON rpm are conformed to:
When the both above conditions 1) and
2) are conformed to.
2. Conditions for OFF (OR circuit)
1) During gear shifting (The status that the
clutch is not completely engaged.)
2) When the right-sided conditions for the
OFF rpm are conformed to.
The status quo is maintained when the conditions of

either 1 or 2 are not conformed to.
10-26
Gear speed
F1
F2, F3,
R1, R2, R3
ON
1,230 rpm
or less
1,260 rpm
or more
OFF
1,200 rpm
or less
1,230 rpm
or more
ON
2,140 rpm
or less
OFF
2,200 rpm
or more
rpm
D375A-5

1. When the machine is in torque converter travel mode
When the machine enters torque converter travel

mode, the solenoid valve is demagnetized to bring
back the plunger (34) upward by oil pressure, opening the seats of valve (27) and ball (28), and the
ports P and N.
Since the drain circuit of the port N is open, the oil at
the port M is drained as well.
The lock-up selector valve (24) is pushed rightward
by the spring (22), closing the ports Q, L, S, and T
and opening the ports Q, S, L, and R.
D375A-5
Then, the oil from the pump goes through the port Q
to the port S to function as the back pressure of the
piston of the stator clutch. It turns ON the stator
clutch after the oil pressure of the circuit goes up.
At the same time, the oil which has been functioning
as the back pressure of the piston of the lock-up
clutch is drained through the port L to the port R,
turning OFF the lock-up clutch.
The oil from the pump also enters the port P. Since
the solenoid valve is demagnetized, however, it is
drained through the orifice A.
The oil pressure at the port Q is kept by the orifice A
and regulated by the modulating valve (10).
10-27

2. When the machine is in direct travel mode
When the machine enters direct travel mode, the solenoid valve is magnetized to push the plunger (34)
downward, closing the seats of ball (28) and valve
(27) to open the ports P and M and close the drain
circuit of the port N.
Then, the oil from M moves the piston (25) and lockup selector valve (24) leftward to close the ports Q,
S, L, and R, and open the ports Q, L, S, and T.
10-28
The oil from the pump goes through the port Q to the
port L to function as the back pressure of the piston
of the lock-up clutch. It turns ON the lock-up clutch
after the oil pressure of the circuit goes up. At the
same time, the oil which has been functioning as the
back pressure of the piston of the lock-up clutch is
drained through the port S to the port T, turning
OFF the stator clutch.
The oil pressure at the port L is regulated by the
lock-up clutch modulating valve (11).
D375A-5

Operation of the stator clutch and lock-up clutch

modulating valves
The modulating valve is mounted at the circuit

between the lock-up selector valve and the inlet
of two pairs of clutches. To smoothly turn on the
clutch, it gradually increases the oil pressure applied to the piston up to the specified level. This
operation reduces a shock to the torque converter or transmission.
In the following operation explanation, the modulating valve for the stator clutch is taken as an example, and that for the lock-up clutch is alike.
The oil flow to the clutch is reverse, however, depending on the direct travel mode or torque converter travel mode.
1. When the machine is in direct travel mode
When the machine enters direct travel mode, the
solenoid valve is magnetized to cause the oil at
the port M of lock-up selector valve (24) to push
the piston (25) and valve (24) leftward.
Then, the lock-up selector valve (24) is pushed
leftward by an oil pressure larger than the tension of the spring (22) to close the ports Q and S
and open the ports S and T, draining the oil at the
port S through the port T.
When the oil pressure at the port S vanishes, the
modulating valve (10) is pushed back by the tension of spring (16) rightward to open the part B
of the port S completely. At that time, the operating pressure of the stator clutch is drained
through the port S to the port T to turn OFF the
clutch.
The oil from the pump flows through the port Q
to the port L to turn ON the lock-up clutch.
D375A-5
10-29

2. When the machine is in torque converter

travel mode
When the machine enters torque converter travel mode, the solenoid valve is demagnetized
to drain the oil from the pump and at the port M.
The valve (24) moves the valve rightward by the
tension of the spring (22) to close the ports Q, L,
S, and T, and open the ports Q and S. By this operation, the circuit from the port Q, the modulating valve (10), and up to the stator clutch is
created.
The oil from the pump flows to the stator clutch
through the port Q to start increasing the oil
pressure of the circuit.
When the oil pressure at the circuit is increased,
the oil which flowed through the orifice d of the
modulating valve (10) pushes the piston (13),
and its reaction force moves the modulating
valve leftward to throttle back the part B of the
port S.
The port S, which is connected to the port U
which applies a back pressure to the load piston
(19), moves the load piston rightward to shrink
the spring (16) to open the part B of the port S
by the tension of the spring.
The above operation is intermittently repeated to
increase the load of the spring (16), gradually increasing the oil pressure until the oil pressure increase stops at a position where the part B of the
port S closes.
The oil pressure of the stator clutch at that time
is 2.65 0.1 MPa {27.0 1 kg/cm2}.
The oil pressure of the lock-up clutch is
2
+1
1.3 +0.1
0 MPa {13 0 kg/cm }.
10-30
D375A-5

SCAVENGING PUMP
SCAVENGING PUMP
BAR 63 + 277
A. Discharge port
B. Small pump suction port
C. Large pump suction port
No.
1
Check item
Criteria
Spline shaft rotation torque

Delivery
Unit: mm
Oil: E010-CD
Oil temperature: 45 55C
Type
BAR 63
BAR 277
D375A-5
Remedy
Rotating
speed
(rpm)
1,743
Discharge
pressure
Standard
discharge
amount
Permissible
discharge
amount
0.15
{1.5}
63.3
276.8
MPa {kg/cm }
(/min)
(/min)
10-31

TRANSMISSION CONTROL
Regarding the steering-related description of the
Palm Command Control System lever (PCCS lever), refer to the Steering/Brake Control.
PCCS: Palm Command Control System
1. Brake pedal
2. Safety lever
3. PCCS lever
(Forward-reverse, gear shift)
3A, UP switch
(Shift up by every one pressing)
3B, DOWN switch
(Shift down by every one pressing)
4. Transmission neutral safety switch
5. Cable
6. Transmission control valve
10-32
Lever position
1:
2:
3:
4:
5:
6:
7:
8:
Neutral
Forward
Reverse
OFF
Shift UP
Shift DOWN
Free
Lock
Outline
Control the transmission by the PCCS lever (3).

The PCCS lever operates forward/reverse
shifting and gear shift operation.
The adopted safety mechanism does not
cause the transmission neutral safety
switch (4) to function except when the
safety lever (2) is at the Lock position, not
allowing the engine to start.
D375A-5

Gear shift of the machine

Since gear shift during travel is possible, there is no
need to stop the machine to shift gears.
Gear shift operation
Operate the gear shift lever by pressing the switches
(1) and (2) when the steering, forward/reverse, and
gear shift lever is at the forward or reverse position.
(1) One pressing the up shifts the gear speed one
up.
(2) One pressing the down shifts the gear speed
one down.
If you carry out the gear shift, the gear speed in
use is indicated on the display of the panel.
<Ex.> Neutral: Indicates N on the display.
Forward 2nd speed gear:
Indicates F2 on the display.
Reverse 3rd speed gear:
Indicates R3 on the display.
P is indicated when the safety lever is
placed at the Lock position.
D375A-5
10-33

TRANSMISSION
TRANSMISSION
1.
2.
3.
4.
Input shaft
Transmission valve
Front case
Rear case
10-34
A.
B.
C.
D.
E.
2nd clutch operating pressure pick-up port

R clutch operating pressure pick-up port
3rd clutch operating pressure pick-up port
F clutch operating pressure pick-up port
1st clutch operating pressure pick-up port
D375A-5

10-36
TRANSMISSION
D375A-5

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

10-38
TRANSMISSION
D375A-5

TRANSMISSION
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
1
2
3
4
No. 1 clutch spring
No. 2 clutch spring

No. 3, 4 clutch spring
No. 5 clutch spring
( 12)
( 12)
( 12)
( 3)
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
66.0
57.0
125.5 N
{12.8 kg}
64.0
107.9 N
{11.0 kg}
70.0
60.3
218.7 N
{22.3 kg}
68.0
196.1 N
{20.0 kg}
97.0
82.4
149.1 N
{15.2 kg}
95.0
127.5 N
{13.0 kg}
7.75
6.75
3,422.5 N
{349 kg}
3,079.3 N
{314 kg}
Standard size
Tolerance
Repair limit
54.6
0.33
49.0
Overall assembled thickness of

No. 2 clutch
50.3
0.33
45.0

No. 3 clutch
36.4
0.26
32.0

No. 4 clutch
27.3
0.22
24.0

No. 5 clutch
50.0
0.33
45.2
10
Thickness of clutch disc

(No. 1 4 clutch)
4.8
0.1
4.0
11
Thickness of clutch disc

(No. 5 clutch)
5.0
0.1
4.2
12
Thickness of clutch plate

(No. 1 4 clutch)
4.3
0.1
4.0
13
Thickness of clutch plate

(No. 5 clutch)
4.0
0.1
3.8
14
Wear of seal ring on transmission

input shaft
Width:
3.0
Thickness: 3.5
Width:
0.01
0.03
Thickness: 0.15
Width:
2.6
Thickness: 3.3
15
Wear of seal ring on transmission

output shaft
Width:
4.5
Thickness: 5.8
Width:
0.01
0.03
Thickness: 0.1
Width:
4.1
Thickness: 5.6
16 Wear of seal ring on No. 5 clutch
Width:
5.0
Thickness: 6.0
Width:
0.01
0.03
Thickness: 0.15
Width:
4.6
Thickness: 5.8

No. 1 clutch
17
Backlash between No. 1, 2 sun

gear and planet pinion
18
Backlash between No. 1 planet

pinion and ring gear inner teeth
Backlash between No. 2, 3, 4

19 planet pinion and ring gear inner
teeth
Standard clearance
Clearance limit
0.13 0.40
0.13 0.40
0.14 0.40
20
Backlash between No. 3, 4 sun

gear and planet pinion
0.13 0.37
21
Clearance between bearing and

thrust washer
0.16 1.59
D375A-5
Replace
10-39

TRANSMISSION
Outline
The transmission is a forward 3 gear, reverse 3

gear transmission that consists of a combination
of a planetary gear system and disc clutches.
The transmission actuates the control valve to
use hydraulic pressure to fix two of the clutches
in the five sets pf planetary gears and disc
clutches to select one rotating direction and one
gear speed.
The clutches are locked as follows: No. 1 clutch
for REVERSE, No. 2 clutch for FORWARD, No. 3
clutch for 3rd, No. 4 clutch for 2nd and No. 5
clutch for 1st.
No. of plates and discs used

Clutch No.
No. of plates
No. of discs
No. 1 clutch
No. 2 clutch
No. 3 clutch
No. 4 clutch
No. 5 clutch
Gear speed, clutch combination.

Gear speed
FORWARD 1st
FORWARD 2nd
FORWARD 3rd
NEUTRAL
REVERSE 1st
REVERSE 2nd
REVERSE 3rd
Clutch combination
(engaged)
No. 2 . No. 5
No. 2 . No. 4
No. 2 . No. 3
1 . No. 5
No. 1 . No. 5
No. 1 . No. 4
No. 1 . No. 3
1: Only low pressure oil fills the 1st clutch.
10-40
D375A-5

TRANSMISSION
Operation of disc clutch
To lock ring gear (7), a disc clutch is used. The

clutch consists of piston (36), plates (38), discs
(39), pins (42) and piston return springs (37).
The internal teeth of the disc engage with the external teeth of the ring gear.
The teeth on the outside diameter of the plate
engage with pins (42) secured by housing (35).
Clutch engaged (Locked)
Oil from the control valve flows under pressure

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

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

TRANSMISSION
1st clutch oil circuit

The 1st clutch is farthest from the control valve, and
the piping to the cylinder is longer, so it takes a longer time for the oil to fill the piping.
For this reason, even when the gear shift lever is in
neutral, oil still flows to the 1st clutch.
Therefore, when moving the gear shift lever from
neutral to F1, it is only necessary for the oil from the
pump to fill the FORWARD clutch.
When the gear shift lever is moved from F1 to F2, the
FORWARD clutch is already filled with oil, so the oil
from the pump only needs to fill the 2nd clutch. By
using the oil in this way, the time lag when shifting
gear is reduced.
10-42
D375A-5

TRANSMISSION
OPERATION OF TRANSMISSION
FIRST FORWARD SPEED
For FORWARD 1st, No. 2 clutch and No. 5 clutch

are engaged. The motive force transmitted from
the torque converter to input shaft (1) is transmitted to output shaft (25).
No. 2 clutch is actuated by the hydraulic pressure
applied by the clutch piston and locks ring gear
(13) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and
engaged No. 5 gear (22) and No. 4 ring gear
(18).
The motive force from the torque converter is
transmitted to input shaft (1). The rotation of the
input shaft is transmitted through sun gear (11)
to planet pinion (12).
D375A-5
Ring gear (13) is locked in position by No. 2

clutch, so planet gear (12) rotates carrier (32),
which is on the inside of ring gear (13).
No. 5 clutch is also engaged, so the No. 5 gear
(22), sun gears (17) and (21), planet pinions, ring
gear (15) and (18), and No. 4 carrier (30) form
one unit. In addition, carrier (32) rotates as one
unit with the gears of No. 3, 4 and 5 clutches to
rotate output shaft (25).
Output shaft (25) rotates at the same speed as
carrier (32).
10-43

TRANSMISSION
FIRST REVERSE SPEED
For REVERSE 1st, No. 1 clutch and No. 5 clutch

are engaged. The motive force transmitted from
the torque converter to input shaft (1) is transmitted to output shaft (25).
No. 1 clutch is actuated by the hydraulic pressure
applied by the clutch piston and locks carrier (34)
in position. No. 5 clutch is actuated by hydraulic
pressure applied by the clutch piston and engaged No. 5 gear (22) and No. 4 ring gear (18).
The motive force from the torque converter is
transmitted to input shaft (1). The rotation of the
input shaft is transmitted through sun gear (6) to
planet pinion (9).
10-44
Carrier (34) is locked in position by No. 1 clutch,

so the rotation of planet pinion (9) rotates ring
gear (10).
Ring gear (10) rotates in the opposite direction
from the input shaft, and it rotates carrier (32).
No. 5 clutch is also engaged, so the No. 5 gear
(22), sun gears (17) and (21), planet pinions, ring
gear (15) and (18), and No. 4 carrier (30) form
one unit.
In addition, carrier (32) rotates as one unit with
the gears of No. 3, 4 and 5 clutches to rotate output shaft (25).
D375A-5

TRANSMISSION ECMV
TRANSMISSION ECMV
(Electronic Control Modulation Valve)
10-46
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Proportional solenoid valve for 3rd clutch ECMV

Proportional solenoid valve for 1st clutch ECMV
Proportional solenoid valve for R clutch ECMV
Proportional solenoid valve for 2nd clutch ECMV
Proportional solenoid valve for F clutch ECMV
Fill switch for 3rd clutch
Fill switch for 2nd clutch
Fill switch for 1st clutch
Fill switch for R clutch
Fill switch for F clutch
Connector for 1st proportional solenoid valve
Connector for 3rd proportional solenoid valve
Connector for R proportional solenoid valve
Connector for 2nd proportional solenoid valve
Connector for F proportional solenoid valve
Connector for 3rd fill switch
Connector for 2nd fill switch
Connector for 1st fill switch
Connector for R fill switch
Connector for F fill switch
Filter
Pressure control valve
Oil pressure detection valve
Pressure control valve spring
A.
B.
C.
D.
E.
F.
P.
T.
1st operating pressure pick-up port

3rd operating pressure pick-up port
R operating pressure pick-up port
2nd operating pressure pick-up port
F operating pressure pick-up port
To clutch
From pump
Drain
D375A-5
TRANSMISSION ECMV
10-47

10-48
TRANSMISSION ECMV
D375A-5

TRANSMISSION ECMV
Outline of ECMV
ECMV and proportional solenoid
The ECMV consists of a pressure regulator valve

and a fill switch.
Converts a current sent from the transmission controller to the proportional solenoid valve, to an oil
pressure.
Fill switch
Detects that the clutch is filled with oil. It has the
functions below.
1) When the clutch is filled with oil, a signal (the
fill signal) is sent to the controller to notify that
filling is finished.
2) While oil pressure is being applied to the
clutch, a signal (the fill signal) is sent to the
controller to notify that oil pressure is being
applied.
A range: Before shifting gear (when drained)
B range: Filling
C range: Pressure regulation
D range: Filling (triggering)
E point: Start of filling
F point: Finish of filling
One proportional solenoid is installed for one

ECMV.
After receiving the command current from the
controller, it produces thrust shown in the graph
below.
By making the proportional solenoid-produced
thrust act on the pressure control valve spool, it
produces an oil pressure shown in the graph below. By controlling the amount of command current, the thrust is changed to operate the pressure
control valve, controlling the oil flow and oil pressure.
Current-Propulsion force characteristics of

proportional solenoid
Propulsion force-Hydraulic pressure characteristics of proportional solenoid
ECMV and fill switch

The logic is such that the controller does not recognize finish of filling even if the fill switch is turned
"ON" during the triggering operation (D range).
D375A-5
One fill switch is installed for one ECMV.

If the clutch finishes filling,the fill switch is turned
"ON" by the pressure of the clutch. By this signal,
the oil pressure starts build-up.
10-49
(7)

ECMV operation
The ECMV is controlled with the command current sent from the controller to the proportional
solenoid and the output signal of the fill switch.
The relationship between the proportional command current for the ECMV, clutch input pressure,
and output signal of the fill switch is shown in the
graph below.
TRANSMISSION ECMV
1. Before shifting gear (when drained)

(A range in chart)
When a current is not carried to the proportional
solenoid (1), the pressure control valve (2) is
draining the oil at the clutch port A through the
drain port Dr.
Since oil pressure is not applied to oil pressure
detector valve (3) at this time,fill switch (4) is
turned "OFF".
A range:Before shifting gear (when drained)

B range:Filling
C range:Pressure regulation
D range:Filling (triggering)
E point:Start of filling
F point:Finish of filling
The logic is such that the controller does not recognize finish of filling even if the fill switch is turned
"ON" during the triggering operation (D range).
10-50
(7)
D375A-5

2. Filling (B range in chart)

If you supply current to the proportional solenoid
(1) with no oil in the clutch, an oil pressure proportional to the solenoid force acts on the chamber B,
pushing the pressure control valve (2) rightward.
As a result, pump port P and clutch port A are
opened and oil starts filling the clutch. If the clutch
is filled with oil,fill switch (4) is turned "ON".
D375A-5
TRANSMISSION ECMV
3. Pressure regulation (C range in chart)

If you supply current to the proportional solenoid
(1), the solenoid produces thrust proportional to
the current. Pressure is regulated by balancing the
thrust of the solenoid, the thrust of clutch port A,
and reaction force of the pressure control spring
(5).
10-51
(7)

TRANSMISSION LUBRICATION RELIEF VALVE
TRANSMISSION LUBRICATION RELIEF VALVE
1. Lubrication oil pressure measurement plug

2. Lubrication relief spool
3. Valve body
Function
The lubrication relief valve is installed to the right

side face of the transmission, and acts to prevent
any abnormal pressure in the transmission lubricating oil.
Cracking pressure: 0.26 MPa {2.7 kg/cm2}
10-52
D375A-5

POWER TRAIN PUMP + LUBRICATION PUMP
POWER TRAIN PUMP + LUBRICATION PUMP

BAL 180 + 112
Unit: mm
No.
Check item
Side clearance
Clearance between plain bearing inside diameter and gear

shaft outside diameter
Criteria
Type
Standard
clearance
Clearance limit
BAL 180
0.07 0.12
0.15
BAL 112
0.04 0.10
0.13
0.060 0.145
0.20
BAL 180
BAL 112
Type
Driving depth of pin
BAL 180
BAL 112

Delivery
Oil: E010-CD

(Engine speed: 1,900 rpm)
D375A-5
Remedy
Standard size
Tolerance
Repair limit
14
0
0.5
Replace
5.9 Nm {0.6 kgm} or less

Type
Rotating
speed
(rpm)
Discharge
pressure
Standard
discharge
amount
Permissible
discharge
amount
MPa {kg/cm }
(/min)
(/min)
BAL 180
2,033
2.5 2.7
{26 28}
334
308
BAL 112
2,033
0.26
{2.7}
210
200
10-53

10 Structure, function and maintenance standard

STEERING, BRAKE CONTROL

Regarding the transmission-related description
of the operation of the PCCS lever, refer to the
Transmission Control.
PCCS: Palm Command Control System
10-54
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Brake pedal
Safety lever
PCCS lever (Steering)
Limit switch
Steering controller
Steering ECMV
Brake valve
Parking brake lever (From safety lever)
Cable
Rod (From brake pedal)
Potentiometer
Positions of lever and pedal

1:
2:
3:
4:
5:
6:
7:
8:
9:
::
A:
Neutral
Forward straight-travel
Reverse straight-travel
Left clutch OFF
Left clutch OFF
Left brake ON
Right clutch OFF
Right clutch OFF
Right brake ON
Brake RELEASE
Brake ON
Free
Lock
Outline
The PCCS lever (3) sends an electric signal to

the steering controller (10). After receiving it, the
steering controller (10) sends a proportional current to the steering ECMV (6) to operate the
steering clutch and brake.
The brake pedal (1) sends an electric signal to
the steering controller (10) via the potentiometer
(11). After receiving it, the steering controller
(10) sends a proportional current to the steering
ECMV (6) to operate the brake. In this case, the
right and left brakes operate at the same time to
activate braking. The rod (5) operates the brake
via the brake valve (9) for redundant use. (Only
at the time of complete braking)
If you slightly tilt the PCCS lever (3) leftward, the
left steering clutch is partially disengaged, causing the machine to make a slow left swing.
D375A-5
If you completely tilt the PCCS lever (3) leftward,

the left steering clutch is turned OFF completely and the left steering brake is turned ON,
causing the machine to make a sudden left
swing.
The safety bar (2) is connected to the parking
brake lever (8) and it also serves as a parking
brake.
10-55

TRANSFER, BEVEL GEAR SHAFT, STEERING
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Transmission unit
Input shaft
Steering unit
Breather
Parking brake valve
Left brake ECMV
Right brake ECMV
Transmission output rotation sensor
Filter
Left clutch ECMV
Right clutch ECMV
Sudden braking prevention valve
D375A-5
10-57

Transfer Bevel Gear Pinion
1.
2.
3.
4.
5.
6.
7.
8.
Input shaft
Drive gear (35 teeth)
Transmission output rotation sensor
Rear cover
Bearing gauge
Driven gear (33 teeth)
Bevel pinion (23 teeth)
Bevel gear (40 teeth)
10-58
Outline
The transfer bevel pinion is mounted at the rear

part inside the steering case, which receives the
power from the transmission output shaft by its
input shaft (1). The transfer consists of the drive
gear (2) and the driven gear (6) to reduce the
power speed from the input shaft (1), transferring
it to the bevel pinion (7). It is also provided with
the transmission output rotation sensor (3) to
send the pulse signal of the drive gear (2) to the
torque converter lock-up controller using an
electric signal.
D375A-5

Unit: mm
No.
Check item
Backlash of transfer gear
Thickness of collar between

transfer gear and bearing
Standard shim thickness for

bearing cage mount
D375A-5
Criteria
Remedy
Standard clearance
Clearance limit
0.24 0.63
0.75
Standard size
Repair limit
24
23.6
2.0
Adjust or replace
Replace
Adjust
10-59

BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE
10-60
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
Clutch cage
Clutch housing
Clutch spring
Clutch piston
Torque pin
Clutch disc (One side: 9 sheets)
Clutch plate (One side: 9 sheets)
Spacer
Clutch stopper
Clutch hub
Bearing cage
Bevel gear (Number of teeth: 40)
Bevel gear shaft
Bevel gear shaft
Bearing cage
Pipe
Brake stopper
Brake hub
Brake disc (One side: 9 sheets)
Spacer
Brake plate (One side: 9 sheets)
Torque pin
Brake piston
Brake case
Brake spring
Brake cage
Sleeve
Output shaft
D375A-5
Outline
As steering clutches, wet-type, multiple disc

type, and spring-boosted types are adopted. If
you operate the PCCS lever, the controller outputs a proportional solenoid current to hydraulically operate the steering ECMV while
interlocking with the brake.
As a lubrication method, forced lubrication is
adopted, which makes oil from the power train oil
cooler flow through the passage in the steering
case to the housing and cage, and up to the disc
plate.
As steering brakes, wet-type, multiple disc type,

and spring-boosted types brakes are adopted. If
you operate the brake pedal and PCCS lever, the
controller outputs a proportional solenoid current
to hydraulically operate the steering valve ECMV
while interlocking with the brake.
As a lubrication method, forced lubrication is
adopted, which makes oil from the power train oil
cooler flow through the passage in the steering
case to the housing and cage, and up to the disc
plate.
When the engine is stopping, the steering brake
is ON since the back pressure of the brake piston lowers unless you press the brake pedal.
Since the brake is released as the oil pressure in
the circuit goes up when the engine restarts, the
parking lock lever must be locked.
10-61

10-62
D375A-5

Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
2.9
2.5
Tolerance
Repair limit
Less than 0.3
0.4
Standard size
Repair limit
4.7
4.2
Tolerance
Repair limit
Less than 0.3
0.4
Standard size
Repair limit
68.4
64.7
68.4
65.4
Standard clearance
Repair limit
0.17 0.52
1.0
Thickness of brake, clutch plate

1
Distortion of brake, clutch plate
Thickness of brake, clutch disc
2
Distortion of brake, clutch
3

brake plates and discs

clutch plates and discs
Backlash between brake, clutch

disc and brake hub
Backlash between bevel gear and

pinion
0.3 0.4
0.75
Clearance between piston seal

ring groove and seal ring
0.5 0.8
0.8
Clearance between cage seal

ring groove and seal ring
0.5 0.8
0.8
10
Inside diameter of cage seal ring

contact surface
Inside diameter of piston seal ring
contact surface
Tolerance
Shaft
Hole
Standard
clearance
290
0.5
0.7
+0.081
0
0.5
0.781
245
0.050
0.122
+0.046
0
0.050
0.168
Standard
size
Standard size
11 Brake belleville spring
12 Clutch belleville spring
13
Interference between bevel gear

and reamer bolt
14 Runout of back face of bevel gear
Replace
Repair or replace
Replace
Repair or replace
Replace
Adjust or replace
Clearance
limit
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
17.1
11.2
38.7 kN
{3,950 kg}
16.5
33.9 kN
{3,460 kg}
17.6
11.35
37.9 kN
{3,860 kg}
17.0
36.0 kN
{3,670 kg}
Standard
size
16
Tolerance
Shaft
Hole
Standard
interference
Interference
limit
+0.019
+0.001
+0.027
0
0.026
0.019
0.02
Repair limit: 0.05 (measure after installing to bevel gear)
Replace
Repair or replace
15
Standard rotating torque: 4.9 5.9 Nm {0.5 0.6 kgm}

Preload of bevel gear shaft taper
(At tip of bevel gear teeth with bevel pinion and gear not meshed: Adjust
roller bearing
23.5 28.4 N {2.4 2.9 kg})
16
Standard shim thickness for bearing cage
D375A-5
2.0
Adjust shim
10-63

STEERING ECMV
STEERING ECMV
(Electronic Control Modulation Valve)
10-64
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
ECMV (For left clutch)

ECMV (For right clutch)
Sudden braking prevention valve
Parking brake valve
ECMV (For left brake)
ECMV (For right brake)
Filter
Valve seat
D375A-5
STEERING ECMV
A.
B.
C.
D.
E.
F.
G.
H.
J.
K.
L.
M.
N.
P.
Left clutch operating pressure pick-up port

Right clutch operating pressure pick-up port
Left brake operating pressure pick-up port
Right brake operating pressure pick-up port
To left clutch
To left lubrication
To left brake
To right clutch
To right lubrication
To right brake
Bevel gear shaft lubrication inlet
To pin puller solenoid valve
From pin puller solenoid valve
From pump
10-65

10-66
STEERING ECMV
D375A-5

STEERING ECMV
Outline
This machine employs four ECMV (electroniccontrolled modulation valve) on the steering control valve.
The steering control valve is provided on respective valve sheets as the assembly.
The steering control valve is situated in the circuit between the power train pump via the main
relief valve and the piston of the steering clutch
and the brake. It is configured with two pairs of
the steering ECMV (right and left) and the brake
ECMV (right and left).
Shifting the PCCS lever (steering and forward/
reverse) right or left disconnects the steering
clutch. Shifting it further turns ON the brake.
The controller sends the instruction to respective
ECMV to cause the gradual or sudden turn
whichever is designated by the operating position of the PCCS lever (steering lever).
Depending on depth of the pedal depression, the
controller instructs ECMV to apply the right and
left brakes to stop the machine.
The controller that is electrically connected to
the PCCS lever and pedal performs above operations by switching the steering control valves
(each ECMV).
The steering control valves feed the oil from the
power train pump to the steering clutch and
brake to operate their disk clutches.
The sudden stop prevention valve disables sudden braking that can result when a failure is detected in the electric systems.
Shifting the parking brake lever to the Lock position switches the port of the parking brake
valve, thereby draining the oil between the
ECMV for left-and-right brakes and the brake. As
the result, the machine brake is turned on.
The parking brake is also connected to the brake
pedal via the linkage.
D375A-5
10-67

STEERING CLUTCH, STEERING BRAKE ECMV

(Electronic control modulating valve)
A: To clutch or brake
P: From pump
T: Drain
Dr: Drain
P1: Clutch or brake pressure pick-up port
P2: Pilot pressure pick-up port
10-68
1.
2.
3.
4.
5.
6.
Fill switch connector

Proportional solenoid connector
Pressure detection valve
Fill switch
Proportional solenoid
D375A-5

Outline of ECMV
The ECMV (Electronic Control Modulating valve)

consists of a pressure control valve and a fill
switch.
This valve allows a proportional solenoid to receive a current sent from a steering controller
and converts it to oil pressure.
Fill switch
This component detects that a clutch is filled with
oil and has the following functions.
1) When the clutch is filled with the oil, at the
same time, a signal (fill signal) is output to
the controller and transmits filling termination.
2) While oil pressure is applied to the clutch,
the signal (fill signal) is output to the controller and transmits the presence of oil pressure.
ECMV and Proportional Solenoid
One proportional solenoid is mounted for each

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

Brake
Outline
This valve sets the steering clutch oil pressure or

the steering brake oil pressure to a set pressure
and switches a circuit to the clutch chamber and
the brake chamber.
D375A-5
10-69

Operation
1. In case of PCCS lever Neutral, brake pedal Released: Straight travel
(Left and right clutch ON, left and right brake Released, parking brake OFF)
In the position of PCCS lever Neutral and brake

pedal Released, because the solenoid valve (1) of
the steering ECMV is deenergized, the sealing portion of the ball (2) is opened.
The oil from the power train pump enters the port
2? of the steering ECMV via the main relief valve.
The oil that entered the port 2? passes through the
orifice = and passes through the sealing portion of
the ball (2), then is drained.
The valve (3) is moved right by the tension of the
spring (4) and closes the 2? and + ports, then
opens the + and ,H ports. At this time, the oil from
the back pressure port of a clutch piston is drained
from the port + and the clutch is set to ON by the
tension of the clutch spring. The oil pressure of the
brake circuit is ensured by the orifice =.
10-70
Further, the proportional solenoid valve (5) of the

brake ECMV is energized and pushes the ball (6) to
the left direction, then closes the sealing portion.
The oil that entered the pump port 2> enters the port, pushes the valve (7) left, opens the 2> and *
ports, and closes the * and ,H ports. The oil that
entered the 2> port passes through the * port and
flows into the back pressure port of the brake piston. Subsequently, the piston moves to the left direction waiting for the rise of the circuit oil pressure
and compresses the brake spring, then sets the
brake Released.
In the parking brake OFF, the parking brake is
closed and the oil of the brake circuit is not drained.
D375A-5

2. When the PCCS lever is actuated halfway to the left: Slow swing
(Left clutch OFF, left brake Semi-released, right clutch ON, right brake Released, parking
brake OFF)
When the PCCS lever is actuated halfway to the

left, the solenoid valve (1) of the left steering ECMV
is energized and pushes the ball (2) to the left direction, then closes the sealing portion.
The oil from the power train pump passes through
the orifice = from the port 2? and enters .. Subsequently, the oil pushes the valve (3) to the left and
opens the 2? and + ports, then closes the + and ,H
ports. The oil of the + port flows into the clutch piston port and becomes the back pressure, then sets
the left clutch to OFF.
Further, the proportional solenoid valve (5) of the
left ECMV is energized and pushes the ball (6) to
the left direction, then closes the sealing portion.
The oil that entered the pump port 2> enters the port and pushes the valve (7) to the left.
Besides, the oil pressure of the port * and later outputs a command current from the controller to the
D375A-5
proportional solenoid valve (5) in accordance with

the stroke of the PCCS lever. When the current
flows into the proportional solenoid (5), the solenoid generates a thrust in proportion to the current.
The sum of the thrust of this solenoid, the thrust
caused by the brake port oil pressure, and the restitution of the pressure control valve spring (8) is
balanced and pressure-adjusted.
Accordingly, if the stroke of the PCCS lever is small,
the oil pressure of the port * and later is also specified high and the brake changes from Released
to Semi-released. If the stroke is large, the oil
pressure is specified low and the brake changes
from Semi-released to ON.
In the parking brake OFF, the parking brake valve
is closed and the oil of the brake circuit is not
drained.
10-71

3. When the PCCS lever is actuated fully to the left: Sudden swing
(Left clutch OFF, left brake ON, right clutch ON, right brake Released, parking brake OFF)
When the PCCS lever is actuated fully to the left

from the state of Section 2, the proportional solenoid valve (5) of the left brake ECMV is deenergized and sets the ball (6) free, then opens the
sealing portion.
Because the oil of the port E passes through the
sealing portion and is drained, the valve (7) is
moved right by the tension of the spring (8).
At this time, the port Pb closes and the port B
and drain port Dr open.
The oil from the power train pump passes
through the orifice b from the port Pb and passes through the sealing portion, then is drained.
The oil pressure of the clutch circuit is ensured
by the orifice b. On the other hand, the oil that
flows into the brake piston port and reached the
back pressure is drained from the port B to Dr.
10-72
The left brake is set to ON by the tension of the

brake spring.
In the parking brake OFF, the parking brake
valve is closed and the oil of the brake circuit is
not drained.
D375A-5

4. In case of brake pedal Stepped on

(Clutch ON, brake ON, parking brake OFF)
When the brake pedal is stepped on, the proportional solenoid valve (5) of the left and right brake
ECMVs is deenergized from energization by the
pedal full actuation.
A command current is output from the controller
to the proportional solenoid valve (5) in accordance with the actuation stroke of the brake pedal. When the current flows into the proportional
solenoid valve (5), the solenoid generates a
thrust that is proportional to the current. The sum
of the thrust of this solenoid, the thrust caused by
the oil pressure of the brake port, and the restitution of the pressure control valve spring (8) is
balanced and oil pressure is specified, thereby
enabling adjustment of the effect of the brake.
Besides, because the PCCS lever is not actuated, the solenoid valve (1) of the left and right
D375A-5
steering ECMVs is deenergized and the left and

right clutches are set to ON.
Further, when the brake pedal is stepped on, the
parking brake valve linked using a linkage is actuated and drains the oil of the brake circuit.
10-73

5. In case of parking brake ON

(Clutch ON, brake ON, PCCS lever Neutral, braking pedal Released)
When the safety lever for the PCCS lever is set

to the position of Locked, the parking brake
valve (1) moves to the left direction and the ports
A, B, and C open. Accordingly, the oil that flows
into the brake piston port and reached the back
pressure passes through the port C from the
ports A and B and is drained. The back pressure
of the brake piston port continues decreasing
and the brake is fully set to ON, then is held in
the state.
Further, because the ports A and B continue being opened together with the drain port C even if
the engine is restarted, the state of the brake
ON is held.
In the parking brake OFF, the parking brake
valve (1) moves right and is closed between the
10-74
port A, port B, and drain port C, then the brake

is set Released by oil pressure.
D375A-5

PARKING BRAKE VALVE
PARKING BRAKE VALVE
Unit: mm
No.
Check item
Clearance between parking brake

valve spool and valve body
Criteria
Standard
size
14
Sliding portion outside diameter

(spool) with dust sealing and Vpacking
Tolerance
Shaft
Hole
Standard
clearance
0.020
0.030
+0.011
0
0.020
0.041
Parking brake valve spool spring
D375A-5
Clearance
limit
0.05
Tolerance
Repair limit
0.020
0.030
13.9
14
Standard size
3
Remedy
Replace
Hard chrome
plating correction
and replace
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
65
47.7
38.2 N
{3.9 kg}
63.1
36.3 N
{3.71 kg}
Replace
10-75

SUDDEN STOPS PREVENTION VALVE
SUDDEN STOPS PREVENTION VALVE
Outline
This sudden stops valve is installed to prevent a

vehicle from being braked suddenly when an error occurs in an electrical system.
When the sudden stops prevention valve (1) is
installed in the drain circuit of the brake ECMV
and the solenoid valve (2) of the brake ECMV is
deenergized, the oil of the brake circuit D is
drained and sudden braking is prevented from
being applied. Accordingly, when the solenoid
valve (3) of the sudden stops prevention valve (1)
is deenergized, the brake is set to Semi-released by throttling the brake drain circuit D that
works as the orifice a circuit.
10-76
D375A-5

FINAL DRIVE
FINAL DRIVE
Outline
The final drive is a single stage spur gear, single

stage planetary gear reduction type.
The lubrication is of splash type using the rotation of the gears.
The final drive can be removed and installed as
a single unit.
Floating seal (1) is installed to the rotating sliding
portion of the sprocket to prevent the entry of dirt
or sand and to prevent leakage of lubricating oil.
D375A-5
10-77

10-78
FINAL DRIVE
D375A-5

1.
2.
3.
4.
5.
6.
7.
Floating seal
Sun gear
Carrier
Hub
Cover
Sprocket boss
Sprocket teeth
FINAL DRIVE
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Floating seal guard

Cover
Planetary pinion
Ring gear
Cover
First gear
First gear hub
First pinion
Final drive case
Bearing cage
Boss
Shaft
Wear guard
Pivot shaft
Unit: mm
No.
Check item
22
Backlash between first pinion and

first gear
23
Criteria
Remedy
Standard clearance
Clearance limit
0.25 0.99
1.5
Backlash between sun gear and

planetary pinion
0.22 0.81
1.5
24
Backlash between planetary

pinion and ring gear
0.25 0.81
1.5
25
Outside diameter of oil seal

contact surface of first pinion
Standard size
Repair limit
115.0
114.9
26
Thickness of thrust collar in roller

bearing of inner body
25.14
24.9
27
Thickness of thrust collar in roller

bearing of first gear boss
10.0
9.5
28
Dimensions from cover mounting

face to button head
24.0
22.5
Clearance between pinion shaft

29
and carrier
Standard
size
85
30
Standard shim thickness of first

pinion bearing cage
31
Dimensions of final cover end

surface and bearing end surface
32 Clearance of floating seal guard
D375A-5
Tolerance
Replace
Shaft
Hole
Standard
clearance
Clearance
limit
0.036
0.058
0.024
0.059
0.023
0.034
0.1
2
7
0
0.2
Adjust
4.1 5.3
10-79

FINAL DRIVE
PATH OF POWER TRANSMISSION
10-80
D375A-5

FINAL DRIVE
The power from the bevel gear and steering

clutch is transmitted to No. 1 pinion (15). It then
passes through No. 1 gear (13), which is meshed
with the No. 1 pinion, and is transmitted to sun
gear (2) to rotate it.
The rotation of sun gear (2) is transmitted to
planet pinion (10), but ring gear (11), which is
meshed with the planet pinion, is fixed to cover
(9), so the planet pinion rotates on its own axis
and moves around the sun gear along the ring
gear.
Then, the rotating force of sun gear (2) forms the
rotating force of carrier (3), which supports the
planet pinion, and is transmitted to sprocket hub
(4).
The direction of rotation of carrier (3) is the same
as that of sun gear (2).
The rotating force transmitted to sprocket hub (4)
is transmitted to sprocket teeth (7).
D375A-5
10-81

TRACK FRAME
TRACK FRAME
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Idler
Recoil spring assembly
Carrier roller
Track frame
Sprocket
Sprocket cover
Track roller bogie
Track roller
Gap
Idler yoke
Cylinder
Guide
10-82
Outline
The track roller adopts a K type bogie mount, thereby increasing

the actual ground contact area between a road surface and a
track shoe in an uneven ground and increasing drawbar pull.
Because a rubber pad is mounted on a K type bogie, the shock
from a road surface is absorbed.
Track roller bogie

Track roller flange type and bogie arrangement
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
No. 7
D375A-5

TRACK FRAME
Unit: mm
No.
Check item
Criteria
Item
Clearance between inner sleeve

13 and adjustment cylinder
protruding portion
14
Clearance between idler bogie

and guide
15 Press fit force of cartridge pin
D375A-5
Repair limit
Bend
Deformation of track frame outer

sleeve
Remedy
7 (Per length 3,000)
Torsion
3 (Per level length 300)
Concave (Pipe portion)
12
Standard
size
60
Tolerance
Shaft
Hole
Standard
clearance
0.15
0.35
+0.3
0
0.15
0.65
Clearance
limit
2.0
Standard clearance
Clearance limit
0 0.5
3.0
245 441 kN {25 45 ton}
Correct or
replace
Replace
Adjust
10-83

RECOIL SPRING
RECOIL SPRING
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Yoke
Nut
Retainer
Recoil spring
Rod
Spring cylinder
Retainer
Holder
Piston
Lubricator (for pumping in and releasing grease)
Grease chamber cylinder
10-84
Outline
Recoil spring (4) is used to adjust the track tension by pumping in or releasing grease from lubr icator (10) to move rod ( 5) forwar d or
backward. The recoil spring (4) also acts to
dampen any sudden shock brought to bear on
the idler.
D375A-5

RECOIL SPRING
Unit: mm
No.
Check item
Criteria
Standard size
Recoil spring
Clearance between outer and

12 inner sleeve sides of outer sleeve
bushing
Remedy
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
1,416
1,230.5
499.7 kN
{50,994 kg}
1,440
458.5 kN
{46,790 kg}
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
380
0.058
0.228
+0.317
+0.060
0.118
0.545
135
0.600
1.000
13
Clearance between adjustment

cylinder and bushing
14
Press fit force of outer sleeve

bushing (outer sleeve side)
49.0 109.8 kN {5.0 11.2 ton}
15
Press fit force of outer sleeve

bushing (inner sleeve side)
91.2 322.6 kN {9.3 32.9 ton}
16
Clearance between recoil spring

mounting nut and lockplate
D375A-5
Clearance Replace
limit
0.8
Adjust
0 1.0
10-85

IDLER
IDLER
10-86
D375A-5

IDLER
Unit: mm
No.
1
Check item
Criteria
Outside diameter of protruding

portion
Remedy
Standard size
Repair limit
927
Outside diameter of tread
880
855
Depth of tread
23.5
Thickness of tread
32.5
20
Total width
294.4
Width of tread
79.0
87.5
Clearance between shaft and

busing
Standard
size
155
Tolerance
Shaft
Hole
Standard
clearance
0.350
0.413
+0.198
0.053
0.297
0.611
Rebuild or
replace
Clearance
limit
Replace bushing
Standard size
Repair limit
252
Rebuild or
replace
Collar width of shaft
Interference between shaft and

ring
Standard
size
95
Tolerance
Shaft
Hole
+0.046
0
0.15
0.20
Standard Interference
interference
limit
Replace ring
0.15
0.246
Standard clearance
Clearance limit
0.49 0.86
10 End play
D375A-5
0.8
Adjust or replace
10-87
4

TRACK ROLLER
TRACK ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
310
300
270
200
270
210
Single flange
60
25
Double flange
60
30
Outside diameter of flange

(outside)

(inside)
Outside diame- Single flange

ter of tread
Double flange
Thickness of
tread
Total width
358
Width of tread (Single flange)
82
Width of tread (Double flange)
82
Width of flange
(Outside double flange)
29
14
Width of flange
(Inside double flange)
27
12
306
10 Collar width of shaft
11
12

bushing

ring
13 End play
10-88
Standard
size
140
Standard
size
75
Tolerance
Shaft
Hole
Standard
clearance
0.350
0.413
+0.260
+0.010
0.360
0.673
Tolerance
Shaft
Hole
+0.046
0
0.13
0.18
Rebuild or
replace
Clearance
limit
interference
limit
0.130
0.226
Standard clearance
Clearance limit
0.44 0.91
Replace bushing
Replace
Adjust or replace
D375A-5

CARRIER ROLLER
CARRIER ROLLER
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
242
Outside diameter of tread
210
185
Width of tread
79
Thickness of tread
40
27.5
Width of flange
23
12

ring
Standard
size
90

support
Standard
size
86
Axial play of roller
D375A-5
Tolerance
Shaft
Hole
+0.245
+0.185
+0.035
0
Tolerance
Shaft
Hole
0
0.2
+0.350
0
Rebuild or
replace
interference
limit
0.150 245
Standard
clearance
Clearance
Replace
limit
0 0.550
Standard clearance
Clearance limit
0.01 0.22
10-89

TRACK ROLLER BOGIE
TRACK ROLLER BOGIE
1.
2.
3.
4.
5.
Guide
Gap
Track roller assembly (Double)
Large bogie
Rubber mount
6.
7.
8.
9.
Small bogie
Track roller assembly
Cover
Cartridge pin
Outline
10-90
The track roller is mounted on

the small bogie (6) respectively
so that the track roller and track
shoe can be touched constantly.
The vehicle body vibration from
a road surface is absorbed by
the rubber mount (5).
D375A-5

TRACK SHOE
TRACK SHOE
Portion P shows the link on the side where the bushing is pressed fitted.
10-92
D375A-5

TRACK SHOE
Unit: mm
No.
Check item
Link pitch
Height of grouser
Total height of shoe
Outside diameter of bushing
Thickness of bushing
Height of link
Thickness of link
Clearance between links

(Busing press fir force)
10
Interference between bushing

and link
Interference between regular pin

and link
11 Shoe bolt
a. Regular link
b. Master link
D375A-5
Remedy
Standard size
Criteria
Repair limit
280.3
283.3
93
30
116
53
Lug welding,
rebuild or replace
Reverse
Standard
size
Light load
Heavy load
98.5
90
92.5
18.8
10.3
12.8
Standard size
Repair limit
181
163
56
38
One side
Both side
1.4
2.8
Standard
size
Reverse or
replace
Reverse or
replace
Rebuild or
replace
Tolerance
Standard
interference
Shaft
Hole
98
+0.622
+0.522
+0.087
0
0.435 0.622
60
+0.426
+0.366
+0.127
+0.053
0.239 0.373
Tightening torque
(Nm {kgm})
Retightening angle
(Angle)
1,372 137 {140 14}
120 10
686.4 68.6 {70 7}
180 10
Adjust or replace
Retightening
10-93


MAIN FRAME
MAIN FRAME
10-94
D375A-5

1.
2.
3.
4.
5.
Main frame
Bracket
Gap
Cushion
Plate
MAIN FRAME
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Cage
Clamp
Seal
Cover
Coupling
Gap
Cushion
Bushing
Flange
Cushion spacer
Unit: mm
No.
Check item
Interference between steering

16
case and bushing
Criteria
Standard
size
Tolerance
Remedy
interference
limit
Shaft
Hole
275
+0.108
+0.056
+0.052
0
0.004
0.108
Min. 0
17
Clearance between steering

frame and final cage
332
0.018
0.075
+0.057
0
0.018
0.132
0.2
18
Clearance between bracket and

cushion
70
+0.018
0.012
+0.046
0
0.018
0.058
0.1
19
Clearance between ripper beam

mounting pin and bushing
120
0.036
0.090
+0.166
+0.028
0.064
0.256
1.5
100
0.036
0.090
+0.287
+0.200
0.236
0.377
1.5
Clearance between ripper

20 cylinder mounting pin and
bushing
21
Clearance between radiator

guard mounting pin and bushing
80
0.030
0.076
+0.371
+0.269
0.299
0.477
1.5
22
Clearance between radiator

guard mounting pin and bushing
90
0.036
0.090
+0.369
+0.267
0.303
0.459
1.0
23
Clearance between equalizer bar

shaft and bushing
120
0.036
0.090
+0.243
+0.101
0.137
0.333
1.0
24
Amount of rubber protrusion on

seal end surface
Standard size
Repair limit
0.5
25 Free height of front mount rubber
105
103
26 Free height of rear mount rubber
58
56
27
Press fit force of ripper beam

mounting bushing
44.1-117.6 kN {4.5 12 ton}
28
Press fit force of ripper

cylinder mounting bushing
58.8-171.6 kN {6 17.5 ton}
29
Press fit force of radiator guard

mounting bushing
98.0-181.4 kN {10 18.5 ton}
30
Press fit force of radiator guard

mounting bushing
58.8-137.3 kN {6 14 ton}
31
Press fit force of equalizer bar

shaft mounting bushing
31.4-105.9 kN {3.2 10.8 ton}
D375A-5
Replace
Adjust
10-95

SUSPENSION
SUSPENSION
1.
2.
3.
4.
5.
6.
7.
Equalizer
Pivot shaft assembly
Cover
Thrust plate
Thrust plate
Pivot shaft
Seal cage
10-96
8.
9.
10.
11.
12.
13.
Cover
Seal
Bushing
Side pin
Center pin
Busing
Outline
For the track frame, the front is set upside down centering around the pivot shaft (6) at the tail.
Further, the equalizer (1) is swung centering around
the center pin (12) and linked with the left and right
track frames using the side pin (11).
D375A-5

SUSPENSION
Unit: mm
No.
14
15
Check item
Clearance between center pin

and bushing
Clearance between side pin and

bushing
Interference between side pin

16
boss and bushing
Criteria
Standard
size
Shaft
Hole
Standard
clearance
120
0.036
0.090
+0.243
+0.101
0.137
0.333
1.0
95
0.048
0.078
+0.015
0.015
0.033
0.093
1.0
Standard
size
160
17
Press fit force of center pin

bushing
18 Press fit force of side pin bushing
D375A-5
Tolerance
Remedy
Tolerance
Shaft
Hole
+0.045
+0.027
0.028
0.068
Clearance
limit
Replace bushing
interference
limit
0.055
0.113
49.0-186.3 kN {5 9 ton}
34.3-73.5 kN {3.5 7.5 ton}
10-97

SUSPENSION
1. Indicates the left of the blade single tilt specifications.

2. Indicates the right of the blade single tilt specifications.
Unit: mm
No.
19
Check item
Interference between thrust
washer and seal
Interference between thrust

20
washer and seal
21
Interference between pivot shaft

and seal
Clearance between pivot shaft

22
and busing
23
Clearance between pivot shaft

and bushing
10-98
Criteria
Standard
size
Tolerance
Remedy
interference
limit
Shaft
Hole
230
+0.213
+0.098
0.180
0.226
0.278
0.439
165
+0.140
+0.100
0.061
0.124
0.161
0.264
213
+0.096
+0.050
0.115
0.187
0.165
0.283
Standard
size
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
175
0.145
0.208
+0.097
+0.029
0.174
0.305
1.0
210
0.170
0.242
+0.072
0
0.170
0.314
1.0
Replace
Replace bushing
D375A-5

WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM

BLADE SYSTEM
SEMI U + TILT
1.
2.
3.
4.
5.
Blade tilt cylinder

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

U-DOZER + DUAL TILT
1.
2.
3.
4.
5.
6.
7.
Blade tilt cylinder

R.H blade lift cylinder
Pitch solenoid valve
Dual tilt solenoid valve
Blade lift valve
Hydraulic filter
10-100
8. Hydraulic tank
9. Ripper Hi valve
10. Work equipment + PPC charge pump
(SAR(4)140 + (3)071 + (1)022)
11. L.H. blade lift cylinder
12. Blade pitch cylinder
D375A-5

RIPPER SYSTEM
MULTIPLE SHANK RIPPER
1. Ripper Hi valve
2. Ripper tilt cylinder
3. Ripper lift cylinder
D375A-5
10-101

GIANT RIPPER
1.
2.
3.
4.
5.

Ripper Hi valve
Ripper tilt cylinder
Ripper lift cylinder
Pin puller cylinder
(from power train hydraulic circuit)
6. Solenoid valve
(for pin-puller)
10-102
D375A-5

PPC CONTROL PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM

BLADE, RIPPER CONTROL
1.
2.
3.
4.
5.
6.
7.
Blade lift valve

PPC charge valve
Accumulator
Ripper control PPC valve
Blade control PPC valve
PPC lock valve
D375A-5
8. PPC charge pump (SAR(1)022)

9. Hydraulic pump (SAR(4)140 + (3)071)
10. Oil cooler (for PPC)
10-103

WORK EQUIPMENT CONTROL
The drawing shows a pitch dozer and pin puller installed vehicle.
10-104
D375A-5

1.
2.
3.
4.
5.
6.
Work equipment safety lever

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

HYDRAULIC TANK
HYDRAULIC TANK
1.
2.
3.
4.
5.
6.
7.
Sight gauge
Oil filler
Valve
Hydraulic filter
Baffle tube
Blade lift valve
Outline
The hydraulic tank has an assembled type (externally installed) main control valve and a builtin hydraulic filter. The tank capacity is 230 and
the amount of oil inside the tank is set at 120 .
P1. From large pump

A. To blade lift cylinder head
B. To blade lift cylinder bottom
P. From small pump
A1. To blade tilt cylinder bottom
B1. To blade tilt cylinder head
A2. To ripper tilt cylinder bottom
B2. To ripper lift cylinder head
A3. To ripper lift cylinder head
B3. To ripper lift cylinder bottom
T. From ripper Hi valve
10-106
D375A-5

PPC CHARGE VALVE
PPC CHARGE VALVE
10-108
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
PPC CHARGE VALVE
Strainer
Body
Piston
Valve
Spring
Relief valve
Sleeve
Screw
Accumulator
Accumulator check valve
Oil cooler bypass valve
Item
Cracking pressure
MPa {kg/cm2}
3.78 {38.5}
Set pressure
MPa {kg/cm2}
4.46 {45.5}
Oil cooler bypass

Cracking pressure
valve
KPa {kg/cm2}
490 49
{5 0.5}
Accumulator
check valve
Cracking pressure
KPa {kg/cm2}
24.5 4.9
{0.25 0.05}
Filter mesh size
24 110
Filtering area
cm2
62.2
Relief valve
C. Oil cooler
P. From PPC pump
P2. To valve
T. To hydraulic tank
Specified value
Strainer
Unit: mm
No.
11
12
Check item
Clearance between relief valve

and spool
Clearance between check valve

and body
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
13
0.040
0.061
+0.018
0
0.040
0.079
0.10
14
0.032
0.059
+0.027
0
0.032
0.086
0.11
Standard size
Clearance
limit
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
39.3
33.1
215.7 N
{22.0 kg}
38.1
204.9 N
{20.9 kg}
14 Oil cooler bypass valve spring
26.3
19.1
37.3 N
{3.8 kg}
25.4
35.3 N
{3.6 kg}
15 Accumulator check valve spring
20.6
19.1
1.96 N
{0.2 kg}
20.0
1.77 N
{0.18 kg}
13 Relief valve spring
D375A-5
Replace
10-109

PPC CHARGE VALVE
1.
2.
3.
4.
5.
6.
Adjustment screw
Lock nut
Sleeve
Main valve spring
Pilot piston
Main valve
Set pressure:
4.46 MPa {45.5 kg/cm2} (At 44.5 /min)
Outline
The PPC charge valve acts to relieve the oil sent

from the pump when the PPC valve is at NEUTRAL.
It also acts to set the pressure sent to the PPC
valve to the set pressure.
Operation
Chamber A is connected to the pump circuit and

chamber C is connected to the tank drain circuit.
The oil passes through the orifice in the main
valve and fills chamber B.
When the pressure in chamber A rises, and the
differential pressure [ 4 (D2d2) pressure of

chamber A] caused by the difference in the area
of diameter D and d reaches the pressure set by
the main valve spring, the main valve opens. The
pressurized oil in chamber A then escapes to
chamber C, so the pressure in chamber A drops.
10-110
D375A-5

ACCUMULATOR
ACCUMULATOR
FOR PPC VALVE
1.
2.
3.
4.
5.
6.
Gas plug
Shell
Poppet
Holder
Bladder
Oil port
Specifications:
Type of gas: Nitrogen
Gas volume: 300 cc
Max. autuation pressure:
3.1 MPa {32 kg/cm2}
Min. autuation pressure:
1.2 MPa {12 kg/cm2}
Function
The accumulator is installed between the PPC

charge pump and the PPC valve. Even if the engine is started with the work equipment still
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 move down
under its own weight.
Operation
After the engine is stopped, when the PPC valve

is at neutral, chamber A inside the bladder is
compressed by the oil pressure in chamber B.
When the PPC valve is operated, the oil pressure in chamber B goes below 2.9 MPa {30 kg/
cm 2}, and the pressure of the nitrogen gas in
chamber A expands the bladder, so the oil in
chamber B acts the pilot pressure and actuates
the main control valve.
D375A-5
10-111

PPC LOCK VALVE
PPC LOCK VALVE
1.
2.
3.
4.
5.
Lever
End cap
Ball
Seat
Body
Outline
The PPC lock valve is installed in the PPC circuit

between the PPC charge valve and PPC valve. If
the work equipment safety lever is placed at the
LOCK position, the PPC lock valve is actuated
together with the work equipment safety lever.
This stops the oil in the PPC circuit and makes it
impossible to operate the work equipment.
10-112
D375A-5

PPC VALVE
PPC VALVE
FOR BLADE LIFT, TILT
1.
2.
3.
4.
5.
Spool
Metering spring
Centering spring
Piston
Disc
10-114
4
6. Nut (for lever joint)

7. Joint
8. Plate
9. Retainer
10. Body
P. From PPC charge valve port P2

(through PPC lock valve)
P1. To blade lift valve (LOWER) port PA
P2. To blade lift valve (RAISE) port PB
P3. To blade tilt valve (left tilt) port PA1
P4. To blade tilt valve (Right tilt) port PB1
D375A-5
TESTI
TESTING AND ADJUSTING
MEASURING FUEL PUMP OUTLET PORT PRESSURE
5. Run the engine at each speed and check that the

signal voltage of the fuel pump pressure sensor
is within the range in the table.
Sensor signal voltage (between C and B):
Engine
speed
Signal voltage
Fuel pump outlet port

pressure (Reference)
700 rpm
1.38 0.21 V
0.55 0.14 MPa

{5.62 1.41 kg/cm2}
800 rpm
1.38 0.21 V
0.55 0.14 MPa

{5.62 1.41 kg/cm2}
1,000 rpm
2.48 0.21 V
1.25 0.14 MPa

{12.70 1.41 kg/cm2}
1,300 rpm
3.00 0.21 V
1.57 0.14 MPa

{16.00 1.41 kg/cm2}
6. After completing the measurement, remove the

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

power source voltage of the fuel pump pressure
sensor is within the following range.
Sensor signal voltage (between A and B):
4.75 5.25 V
D375A-5
20-114-1
4
MEASURING FUEL PUMP INLET PORT PRESSURE

(NEGATIVE PRESSURE)
MEASURING FUEL PUMP INLET PORT PRESSURE

(NEGATIVE PRESSURE)
Tools for measuring fuel pump inlet port pressure (negative pressure)
Symbol
Part Name
799-101-5002
Hydraulic tester
790-261-1203
Digital hydraulic tester
795-799-5550
Adapter
795-799-5560
Negative pressure gauge

(0 0.1 MPa)
{0 1 kg/cm2}
1
H
Part No.
1. Fit adapter H3 to pump inlet port pressure measuring nipple (3).

2. Fit nipple [1] of hydraulic tester H1 to adapter H3,
install them to coupler (3) of the fuel pump, and
connect negative pressure gauge H4.
If Pm kit (A) is available, the air bleed

coupling (790-261-1130) inside the kit
can be used.
If there is oil inside the hose, the gauge
will not work, so always bleed the oil.
4. Run the engine at each engine speed and measure the pump inlet port pressure.
Fuel pump inlet port pressure
Fuel filter
Fuel pump inlet port pressure
New
Max. 13.60 kPa

{Max. 102 mmHg}
Used
Max. 27.10 kPa

{Max. 203 mmHg}
3. Run the engine at a medium speed to bleed the

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

PPC VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
34.0 15.5
31.9
94 N
{9.6 kg}
75.2 N
{7.67 kg}
12 Metering spring (for P1, P2)
27.23 8.14
24.9
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
13 Centering spring (for P2)
43.2 15.5
31.9
96.1 N
{9.8 kg}
76.5 N
{7.8 kg}
14 Centering spring (for P3, P4)
48.57 15.5
31.9
111.8 N
{11.4 kg}
89.4 N
{9.1 kg}
15 Metering spring (for P3, P4)
26.53 8.15
24.9
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
16 Detent spring (for P1)
20.39 19.5
13.1
159.36 N
{16.25 kg}
127.5 N
{13 kg}
17 Detent spring (for P2)
45.36 7.5
26
38.44 N
{3.92 kg}
30.79 N
{3.14 kg}
11 Centering spring (for P1)
D375A-5
Replace spring
if damaged or
deformed
10-115

PPC VALVE
Operation
1) At neutral
(i) PPC valve for blade lift
Ports PA and PB of the blade lift control valve,
and ports P1 and P2 of the PPC valve are connected to drain chamber D through fine control
hole f in spool(1).
(ii) PPC valve for blade tilt

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

PPC VALVE
2) During fine control (neutral fine control)

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

PPC VALVE
3) During fine control

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

PPC VALVE
5) Blade operated to FLOAT

When piston (4) at port P1 (LOWER side) is
pushed by disc (5) and moves down, protrusion
a of the piston contacts ball (11) during the
downward stroke. (The detent starts to be actuated.)
If piston (4) is pushed further, ball (11) pushes up
collar (12), which is being held by detent spring
(13), and moves to the outside, so the ball passes over protrusion a of the piston. At this point,
piston (4') at the opposite side is pushed up by
the spring (14).
As a result, the oil inside chamber F flows
through b and c and enters chamber E, and piston (4') follows disc (5). Passage d is interconnected with port P1, so it is under more or less
the same pressure as port P1.
Chamber E is normally interconnected with drain
chamber D, but when ball (11) passes over protrusion a of the poston, passage d and chamber
E (which were shut off) are interconnected and
pressurized oil flowa. At the same time, the control valve also moves to the FLOAT position, so
the blade circuit is set to the FLOAT condition.
The pressurized oil inside chamber E pushes up
piston (4'), so even of the lever is released, it is
held at the FLOAT position.
6) Blade released from FLOAT
When disc (5) is retuned from the FLOAT position, it is pushed down by a force greater than the
pressure of the oil in chamber E.
For this reason, chamber E is shut off from passage d and is connected to the drain chamber.
Therefore, the oil pressure inside chamber E is
lost, and the FLOAT, position is released.
D375A-5
10-119

PPC VALVE
FOR RIPPER
1.
2.
3.
4.
5.
6.
Spool
Metering spring
Centering spring
Piston
Disc
Nut (for lever joint)
10-120
7. Joint
8. Plate
9. Retainer
10. Body
11. Filter
P. From PPC charge valve port P2

(through PPC lock valve)
P1. To ripper tilt valve (TILT BACK) port PB2
P2. To ripper tilt valve (TILT IN) port PA2
P3. To ripper tilt valve (LOWER) port PA3
P4. To ripper tilt valve (RAISE) port PB3
D375A-5

PPC VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Remedy
Repair limit
Free length
O.D.
Installed
length
Installed
load
Free length
Installed
load
50.4 15.5
34
55.9 N
{5.7 kg}
45.1 N
{4.6 kg}
13 Metering spring
26.6 7.5
24.9
16.7 N
{1.7 kg}
13.7 N
{1.4 kg}
50.1 15.5
34
71.6 N
{7.3 kg}
56.9 N
{5.8 kg}
D375A-5
Replace spring
if damaged or
deformed
10-121

PPC VALVE
Operation
1) At neutral
Ports PA2, PA3, PB2 and PB3 of the ripper control valve and ports P1, P2, P3, and P4 of the
PPC valve are connected to drain chamber D
Through fine control hole f of spool (1).
2) During fine control (neutral fine control)

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

PPC VALVE
3) During fine control

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


WORK EQUIPMENT CYLINDER
BLADE LIFT CYLINDER
BLADE TILT CYLINDER
PIN PULLER CYLINDER
10-124
D375A-5

Unit: mm
No.
Check item
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearance
limit
Blade
LIFT
90
0.036
0.090
+0.270
+0.061
0.097
0.360
0.693
Blade
TILT
110
0.036
0.090
+0.274
+0.060
0.096
0.364
Pin
puller
30
0.065
0.117
+0.133
+0.007
0.072
0.250
0.55
Clearance between
piston rod spherical
surface and blade ball
portion
Blade
LIFT
100 (Ball)
+0.300
0.300
1.0
Clearance between
cylinder support shaft
bushing and yoke
Blade
LIFT
105
0.120
0.207
+0.035
0
0.120
0.242
0.5
Thickness of standard
shim between tip of
piston rod and cap
Blade
LIFT
Clearance between
piston rod and bushing
Clearance between
piston rod support shaft
and bushing
Blade
TILT
4.0
Standard
size
Tolerance
Adjust
Shaft
Hole
Standard
clearance
Clearance
limit
75
0.200
0.300
+0.200
0
0.200
0.500
1.0
Clearance between
Blade
cylinder bottom support
TILT
shaft and bushing
75
0.200
0.300
+0.174
+0.100
0.300
0.474
1.0
Clearance between
piston rod spherical
surface and cap
Pin
puller
29
0.100
0.200
+1.300
+1.200
1.3 1.5
Clearance between
Pin
puller
shaft and boss
26
1.1
1.2
0.1
1.0 1.3
D375A-5
Replace
Replace
10-125

RIPPER LIFT CYLINDER
RIPPER TILT CYLINDER
Unit: mm
No.
Check item
Criteria
Standard
size
Clearance between
piston rod and bushing
Shaft
Hole
Standard
clearance
Clearance
limit
Ripper
LIFT
110
0.036
0.123
+0.274
+0.060
0.096
0.397
0.697
Ripper
TILT
110
0.036
0.123
+0.274
+0.060
0.096
0.397
0.697
100
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
100
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
100
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
100
0.036
0.090
+0.207
+0.120
0.156
0.297
1.0
Ripper
Clearance between
LIFT
piston rod support shaft
Ripper
and bushing
TILT
Ripper
Clearance between
LIFT
Ripper
shaft and bushing
TILT
10-126
Tolerance
Remedy
Replace
D375A-5

PISTON VALVE
PISTON VALVE
(BLADE LIFT CYLINDER)
Outline
The piston valve is installed on the piston in the

blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston.
In addition the piston valve relieves the shock
which occurs when the piston comes into contact
with the cylinder head or the bottom and serves
to reduce the subsequent surge pressure in the
cylinder by letting the oil escape from the cylinder before the piston reaches its stroke end.
Operation
1. Piston valve CLOSED
Pressurized oil from the hydraulic pump acts on
piston (2) and piston valve (3).
The piston valve (3) is pushed in the direction of
the arrow until piston valve seat (4) comes into
snug contact with the tapered section, thereby,
this causing the pressure in the cylinder to rise
and moving piston (2) in the direction of the arrow.
2. Piston valve OPEN

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

QUICK DROP VALVE
QUICK DROP VALVE

(BLADE LIFT CYLINDER)
Structure
The quick drop valve consists of valve body (1),

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

QUICK DROP VALVE
Unit: mm
No.
Check item
Clearance between spool and

valve body
Criteria
Standard
size
38.0
Tolerance
Shaft
Hole
Standard
clearance
0.011
0.016
+0.010
0
0.011
0.026
Standard size
2
Valve spring
D375A-5
Remedy
Clearance
limit
0.03
Repair limit
Free length
Installed
length
Installed
load
Free length
Installed
load
75.2
55.9
136.3 N
{13.9 kg}
67.7
122.6 N
{12.5 kg}
Replace
10-129

PIN PULLER SWITCH
PIN PULLER SWITCH
Function
The pin puller solenoid valve is controlled by

turning the pin puller switch ON/OFF.
This changes the oil circuit to the pin puller cylinder and sets the shank mounting pin to the
PUSH IN or PULL OUT position.
10-130
1.
2.
3.
4.
Connector
Wire
Switch
Knob
D375A-5

PIN PULLER SOLENOID VALVE
1.
2.
3.
4.
5.
6.
7.
8.
9.
Plug
Spring
Spring retainer
Valve body
Spool
Spring retainer
Spring
Push pin
Solenoid assembly
D375A-5
A.
B.
P.
T.
To pin puller cylinder bottom

To pin puller cylinder head
From power train pump
To steering case
10-131

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

When the pin puller switch is set to the PULL
OUT position, electricity flows to solenoid (9) and
it is excited.
Then, the solenoid pushes out push pin (8) and
spool (5) moves to the left in the arrow direction.
At this point, ports P and A and ports B and T
close, and ports P and B and ports A and T
open, so the oil from the power train pump flows
from port P to port B and enters the head end of
pin puller cylinder (10).
When the oil enters the cylinder head end and
the pressure in the circuit rises, the cylinder retracts and pulls shank mounting pin (11) out of
shank (12).
10-132
D375A-5

BLADE CONTROL KNOB
BLADE CONTROL KNOB
1.
2.
3.
4.
5.
Switch (Dual, single tilt switching)

Switch (Pitch)
Cover
Connector (Male)
Connector (Female)
Outline
By setting the blade control knob to the front and

the rear or the left and the tight, the blade is
raised or lowered and tilted left or right. Further,
by setting the switch (1) to the DUAL side and
setting the lever to the left and right, the dual tilt
actuation is performed. Also by setting the lever
to the left and right pressing (2), the pitch actuation is performed.
D375A-5
When the switch (2) is pressed and the lever is

actuated, the blade is pitched. When the lever is
set to the left, the blade is pitched back. When
the lever is set to the right, the blade is pitchdamped.
When the switch (1) is set to the DUAL side and
the lever is actuated, the blade is dually tilted.
When the lever is set to the left, the blade is dually tilted left. When the lever is set to the right,
the blade is dually tilted right.
Even if the switch (1) is switched to either DUAL
or SINGLE, the blade is pitched when the lever
is set left and right pressing the switch (2).
10-133

PITCH, DUAL TILT SOLENOID VALVE

MACHINES EQUIPPED WITH DUAL TILT
1. Main spool assembly

2. Pilot solenoid assembly
3. Connector
A.
B.
T1.
T2.
P1, P2.
P.
T.
To R.H. blade pitch (dual tilt) cylinder bottom

To R.H. blade pitch (dual tilt) cylinder head
To L.H. blade pitch (dual tilt) cylinder bottom
To L.H. blade pitch (dual tilt) cylinder head
From blade tilt control valve
From PPC charge valve
To hydraulic tank
10-134
Function
This valve is installed between the blade tilt,

pitch cylinder and the blade tilt, ripper Lo valve. It
acts to open or close the hydraulic circuit to the
blade tilt or pitch cylinder according to the pitch
or dual tilt switch signal.
D375A-5

Operation
Pitch switch ON
When pitch switch (1) is operated, electricity

flows to pitch solenoid valve (2) and it is excited.
When this happens, main spool (4) opens the
circuit between port T1 and B and between A
and P1, and the hydraulic circuit is connected to
the bottom end of left pitch cylinder (5) and to the
head end of right pitch cylinder (6). As a result,
both the right pitch cylinder and left pitch cylinder
are retracted and the blade is pitched to the rear.
Dual tilt switch ON
When dual pitch switch (2) is operated, electricity

flows to dual tilt solenoid valve (3) and it is excited. When this happens, main spool (4) opens
the circuit between port T2 and B and between
A and P2, and the hydraulic circuit is connected
to the head end of left tilt cylinder (5) and to the
bottom end of right tilt cylinder (6). As a result,
the left dual tilt cylinder is extended and the right
dual tilt cylinder is retracted to tilt the blade.
D375A-5
10-135

WORK EQUIPMENT + PPC CHARGE PUMP

SAR(4)140 + (3)071 + (1)022
10-136
D375A-5

Unit: mm
No.
Check item
Side clearance
Clearance between plain bearing

inside diameter and gear shaft
outside diameter
Driving depth of pin
Criteria
Type
Standard clearance
Clearance limit
SAR(4)-140
0.11 0.16
0.19
SAR(3)-071
0.10 0.15
0.19
SAR(1)-022
0.10 0.15
0.19
SAR(4)-140
0.060 0.140
0.20
SAR(3)-071
0.060 0.149
0.20
SAR(1)-022
0.060 0.144
0.20
Type
Standard size
Tolerance
Repair limit
SAR(4)-140
21
0
0.5
SAR(3)-071
14
0
0.5
SAR(1)-022
10
0
0.5
Oil: EO10-CD
D375A-5
Replace
16.7 26.5 Nm {1.7 2.7 kgm}

Type
Delivery
Remedy
Rotating
speed
(rpm)
Discharge
pressure
Standard
discharge
amount
Permissible
discharge
amount
MPa {kg/cm }
(/min)
(/min)
SAR(4)-140
2,200
20.6
{210}
287
266
SAR(3)-071
2,200
20.6
{210}
137
125
SAR(1)-022
2,200
4.9
{50}
43
39
10-137

MAIN CONTROL VALVE
MAIN CONTROL VALVE

BLADE LIFT VALVE
Outline
Demand valve (14) is assembled to the blade lift

valve, and the oil from the two hydraulic pumps
is merged by check valve (4).
With the demand valve, the oil from the large
pump becomes the pilot pressure, and at the
same time, the oil from the ripper circuit or the
blade lift circuit through shuttle valve (18B) also
becomes the pilot pressure, so the oil from the
two hydraulic pumps is used efficiently.
10-138
P1.
P2.
A.
B.
T.
PA.
PB.
PL.
From large pump

From small pump
To blade lift cylinder head
To blade lift cylinder bottom
To hydraulic tank
From blade lift PPC valve port P2
From blade lift PPC valve port P1
From ripper Lo valve
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
Check valve spring

Small pump circuit check valve
Check valve
Check valve spring
Valve body
Return spring
Blade lift valve
Shuttle valve seat (plug)
D375A-5
MAIN CONTROL VALVE
9.
10.
11.
12.
13.
14.
15.
16.
Shuttle valve ball

Retainer
Return spring (for FLOAT)
Case
Demand valve spring
Demand valve
RAISE suction valve
17. Suction valve spring

18. LOWER suction valve
19. Main relief, shuttle valve
assembly
19A. Main relief valve
19B. Shuttle valve
10-139

MAIN CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Spool return spring
Remedy
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
69.9
63
431.5 N
{44 kg}
345.2 N
{35.2 kg}
Spool return spring
80.69
76.5
400.1 N
{40.8 kg}
319.7 N
{32.6 kg}
Spool return spring (for floating)
43.82
32.5
588.4 N
{60 kg}
470.7 N
{48 kg}
Check valve spring
75.7
43.5
9.8 N
{1.0 kg}
69.3
7.9 N
{0.8 kg}
Check valve spring
32.7
24.5
44.1 N
{4.5 kg}
31.0
35.3 N
{3.6 kg}
Suction valve spring
75.9
38.5
11.38 N
{1.16 kg}
68.4
9.12 N
{0.93 kg}
Demand spool spring
74.5
55
235 N
{24 kg}
10-140
Replace
D375A-5

MAIN CONTROL VALVE
MAIN RELIEF, SHUTTLE VALVE
10-142
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
MAIN CONTROL VALVE
Overview
Valve body
Piston
Shuttle valve
Shuttle valve spring
Plug
Valve seat
Main relief valve poppet
Sleeve
Main relief pressure adjustment screw
PL.
PB.
PD.
T.
From shuttle valve inside ripper valve

From shuttle valve inside blade lift valve
Inside demand valve pilot port
To hydraulic tank
The main relief valve exists in the blade lift circuit

via the shuttle valve (3) and the circuit between
the ripper circuit and the hydraulic tank, and the
oil pressure of the blade lift circuit, that is, a large
pump circuit is set to 20.6 MPa {210 kg/cm2}.
The shuttle valve exists in the blade lift circuit
and the circuit between the ripper circuit and the
demand valve via the main relief valve, and two
circuits that applies the pilot pressure to the demand valve are selected. That is, either the blade
lift circuit or the ripper circuit is selected.
Besides, the shuttle valve connects the blade lift
circuit and the pilot port of the demand valve by
the tension of the spring (4) when work equipment is not used (control lever Neutral).
Unit: mm
No.
Check item
Criteria
Standard size
Shaft valve spring
10
Height of main relief pressure

adjustment screw
D375A-5
Remedy
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
42.7
22.0
8.14 N
{0.83 kg}
38.6
6.47 N
{0.66 kg}
41.1
32.6
258.9 N
{26.4 kg}
39.4
206.9 N
{21.1 kg}
8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2})
Replace
Adjust
10-143

MAIN CONTROL VALVE
BLADE TILT, RIPPER LO VALVE
P.
A1.
B1.
A2.
From small pump

To blade tilt cylinder bottom
To blade tilt cylinder head
To ripper tilt cylinder bottom
(through ripper Hi valve PA1)
B2. To ripper tilt cylinder head
(through ripper Hi valve PB1)
A3. To ripper lift cylinder head
(through ripper Hi valve PB2)
B3. To ripper lift cylinder bottom
(through ripper Hi valve PA2)
10-144
CO.
PL.
PA1.
PA2.
PA3.
PB1.
PB2.
PB3.
To demand valve
To shuttle valve inside blade lift valve
To blade tilt PPC valve P3 (left tilt)
To ripper tilt PPC valve P2 (tilt in)
To ripper lift PPC valve P3 (lower)
To blade tilt PPC valve P4 (right tilt)
To ripper tilt PPC valve P1 (tilt back)
To ripper lift PPC valve P4 (raise)
D375A-5

1.
2.
3.
4.
5.
6.
7.
8.
Blade tilt valve

Ripper tilt valve
Ripper lift valve
Valve body
Return spring
O-ring
Case
Main relief pressure
adjustment screw
D375A-5
MAIN CONTROL VALVE
9.
10.
11.
12.
13.
14.
15.
16.
Sleeve
Main relief valve body
Poppet spring
Main relief valve poppet
Valve seat
Main relief valve
Valve seat
17.
18.
19.
20.
21.
22.
Check valve
Check valve spring
Valve seat
Shuttle valve ball
Shuttle valve seat
10-145

MAIN CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Spool return spring
Remedy
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
52.18
50.0
117.7 N
{12.0 kg}
94.1 N
{9.6 kg}
Check valve spring
28.0
18.0
6.9 N
{0.7 kg}
26.0
5.5 N
{0.56 kg}
24.2
18.3
31.4 N
{3.2 kg}
23.0
25.1
{2.56 kg}
Main relief valve poppet spring
41.1
32.6
258.9 N
{26.4 kg}
39.4
206.9 N
{21.1 kg}
Height of main relief pressure

adjustment screw
10-146
8 (1 turn of screw adjusts by 2.4 MPa {24.8 kg/cm2})
Replace
Adjust
D375A-5

MAIN CONTROL VALVE
RIPPER HI VALVE
P.
PA1.
PB1.
PA2.
PB2.
A1-1.
B1-1.
A1-2.
B1-2.
A2-1.
B2-1.
A2-2.
B2-2.
D375A-5
From small pump

From Lo valve tilt in
From Lo valve tilt back
From Lo valve ripper raise
From Lo valve ripper lower
To L.H. tilt cylinder bottom
To L.H. tilt cylinder head
To R.H. tilt cylinder bottom
To R.H. tilt cylinder head
To L.H. lift cylinder bottom
To L.H. lift cylinder head
To R.H. lift cylinder bottom
To R.H. lift cylinder head
10-147

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Valve body
Shuttle valve seat
Shuttle valve ball
Valve body
Plug
Fixed differential pressure valve spring
Fixed differential pressure valve
10-148
MAIN CONTROL VALVE
11.
12.
13.
14.
15.
16.
17.
18.
19.
Plug
Check valve spring
Check valve
Valve return spring
Plug
Ripper lift Hi valve
Suction valve
Ripper tilt Hi valve
D375A-5

MAIN CONTROL VALVE
Unit: mm
No.
Check item
Criteria
Standard size
Hi valve return spring
Remedy
Repair limit
Free
length
Installed
length
Installed
load
Free
length
Installed
load
79.5
42.0
152.0 N
{15.5 kg}
72.0
121.6 N
{12.4 kg}
Check valve spring
32.6
27.0
30.2 N
{3.08 kg}
31.5
24.1
{2.46 kg}
75.7
43.5
9.8 N
{1.0 kg}
69.3
7.9 N
{0.8 kg}
Constant differential pressure

valve spring
57.4
33.5
169.7 N
{17.3 kg}
52.6
135.3 N
{13.8 kg}
D375A-5
Replace
10-149

MAIN CONTROL VALVE
Operation
1. Blade lever at HOLD, ripper lever at HOLD
10-150
D375A-5

When the blade is at the HOLD position, the

spool of the PPC valve directly connected to the
control lever is not actuated; blade lift spool (5)
closes the circuit from port B to ports C and D,
and opens the circuits of ports H and E and ports
J and F; blade tilt spool (16) close the circuit from
port B3 to ports C3 and D3.
Therefore, the circuits for blade lift cylinder (9)
and blade tilt cylinder (17) become closed circuits, and the cylinders are held in the same position.
If the ripper lever is placed at the HOLD position,
the spool of the PPC valve directly connected to
the control lever does not move; ripper tilt spool
(19) closes the circuit from port B4 to ports C4
and D4, and ripper lift spool (21) closes the circuit from port B5 to ports C5 and D5. Therefore,
the circuits for ripper tilt cylinder (45) and ripper
lift cylinder (33) become closed circuits through
the two ripper valves, and the cylinders are kept
in the same position.
If the engine is started in this condition, the oil
from the large pump enters port A of the blade lift
valve. Some of the oil pushes open check valve
(3) and enters port B where it stops. The rest of
the oil passes through orifice a of demand valve
(1), and enters ports L and M. (The demand
valve is pushed to the right by the tension of
spring (2).)
The oil from the large pump flows to the blade lift
valve, but it also enters port A1 of the ripper Hi
valve, pushes open the two check valve (23) and
(35), then enters ports B1 and B2 and stops.
The oil from the small pump flows from port A2
of the ripper Lo valve and blade tilt valve to ports
A3, A4, and A5. Some of the oil pushes open
check valves (15), (18) and (20), then enters
ports B3, B4 and B5, and stops. The rest of the
oil flows from port A5, enters port R of the blade
lift valve, pushes open check valve (4), and flows
to port A where it merges with the oil from the
large pump.
D375A-5
MAIN CONTROL VALVE
When oil is drained
In the condition already explained, if the hydraulic pressure in the circuit rises, the surface pressure (force pushing the demand valve to the left)
on port L of demand valve (1) becomes greater
than the combined force (force pushing the demand valve to the right) of the surface pressure
bearing on port M and tension of spring (2), it
moves the demand valve to the left, opens the
circuit between ports A and E, and ports R and
F. The oil from the large and small pumps is then
relieved to ports E and F and is drained from port
G to the hydraulic tank.
Therefore, both the large and small pumps are
put in an unload condition.
10-151

MAIN CONTROL VALVE
2. Blade lever at RAISE (blade operating at high speed)
10-152
D375A-5

MAIN CONTROL VALVE
When the blade lever is moved fully to the RAISE

position, the spool of the PPC valve directly connected to the control lever is actuated. When this
happens, the pilot pressure entering the PPC
valve from the PPC pump is sent to port PB of
the blade lift valve. This pilot pressure moves
spool (5) to the left to the end of its stroke, and
fully opens the circuits between ports B and C,
ports C and H, and ports D and F.
When this happens, the oil from the two pumps
passes from ports A and B and enters port C.
Some of the oil flows to the head end of cylinder
(9), and the rest flows from ports H and H', pushes shuttle valve (8) to the right and opens it,
flows to port K, and enters ports N, O, and P of
shuttle valve (10). It then enters port Q of demand valve (1) and becomes the pilot pressure.
At the same time, the oil from the pump passes
through orifice a of demand valve (1), enters
ports L and M, and becomes the pilot pressure.
The oil at the bottom end of cylinder (9) flows
from port D to port F, and returns from port G to
the hydraulic tank. When the hydraulic pressure
in the circuit rises in this way, spool (5) opens the
circuit between ports B and C fully, so the resistance of the oil flowing from port B to port C is
small, and there is little pressure difference generated between port B and port C.
Therefore, no pressure difference is generated
between port L and ports M and Q of the demand valve. The surface pressure acting on the
left and right of the demand valve is equal, so the
demand valve is moved to the right by the tension of spring (2).
When this happens, the circuits between ports A
and E', and ports R and F' are closed, and all the
oil from both the large and small pumps flows to
the head end of the cylinder to increase the
speed of movement of the cylinder.
D375A-5
10-153

MAIN CONTROL VALVE
3. Blade lever at RAISE (blade operating at low speed)
10-154
D375A-5

When the blade lever is operated slightly to the

RAISE position the spool of the PPC valve directly connected to the control lever is actuated.
When this happens, the pilot pressure entering
the PPC valve from the PPC pump is sent to port
PB of the blade lift valve. This pilot pressure
moves spool (5) slightly to the left to a point
where the pilot pressure and the force of the
spring are in balance, and partially opens the circuit between ports B and C, ports C and H, and
Ports D and F.
When this happens, the oil from the two pumps
passes from ports A and B, is throttled by spool
(5) and enters port C. Some of the oil flows to the
head end of cylinder (9), and the rest flows from
ports H and H', pushes shuttle valve (8) to the
right and opens it, flows to port K, and enters
ports N, O, and P of shuttle valve (10). It then enters port Q of demand valve (1) and becomes the
pilot pressure.
At the same time, the oil from the pump passes
through orifice a of demand valve (1), enters
ports L and M, and becomes the pilot pressure.
The oil at the bottom end of cylinder (9) flows
from port D to port F, and returns from port G to
the hydraulic tank. When the hydraulic pressure
in the circuit rises in this way the situation is different from in item 2: spool (5) is throttling the circuit between ports B and C, so the flow of oil
from port B to port C is restricted, and a pressure
difference is generated between port B and port
C. The hydraulic pressure in the circuit up to port
B becomes higher.
Therefore, when the surface pressure acting on
port L of the demand valve becomes greater
than the combined force of the surface pressure
acting on port M, the surface pressure (low pressure) acting on port Q, and the tension of spring
(2), the demand valve is moved to the left.
When this happens, the circuits between ports A
and E', and ports R and F' are opened, and the
oil from both the large and small pumps is relieved to the hydraulic tank. This suppresses the
rise in the hydraulic pressure at ports A and B,
and the cylinder moves slowly.
As explained in the items above, the speed of
movement of the cylinder is determined by the
amount of opening of ports B and C, which corresponds to the movement of the lever. If it is
wide open, the flow of oil beyond port C increases, the hydraulic pressure rises, and the speed
of movement becomes faster.
D375A-5
MAIN CONTROL VALVE
If it is opened only slightly, the flow of oil beyond

port C is throttled, so the oil flow is reduced, the
hydraulic pressure becomes low, and the speed
of movement is slow.
In other words, the hydraulic pressure and oil
flow beyond port C is proportional, so this provides operation of the blade that follows the fine
movement of the blade lever.
When cylinder is at stroke end
If cylinder (9) moves to the end of its stroke from

the condition in items 2 and 3, the hydraulic pressure in the whole circuit rises.
Therefore, the hydraulic pressure beyond port C
rises, and the oil entering the main relief valve
through shuttle valves (8) and (10) (that is, the oil
at port P) pushes open poppet (13) and is relieved to port T.
At this point, the circuit from port O to port P is
throttled by orifice c, so the supply of oil to port P
is delayed. As a result, the hydraulic pressure of
pilot port Q of demand valve (1) drops, and the
demand valve moves to the left.
When this happens, the circuit between ports A
and E' and ports R and F' are opened, and the
oil from the two pumps is relieved to prevent the
hydraulic pressure from rising any further.
The hydraulic pressure at this point is 20.6 MPa
{210 kg/cm2}.
10-155
ADJUSTMENT OF PCCS LEVER POTENTIOMETERS

When adjusting the lever assembly
independently
1. Position lever in NEUTRAL (both forward & reverse, steering)

2. Using tester (2), measure resistance between
5 V pin and signal pin. (See table 1).
(ex. For ST1, measure resistance between pins
A (5 V) and H (SIG))
signal pin and GND pin. (See table 1).
(ex. For ST1, measure between pins H (SIG) and
G (GND))
4. Adjust resistance to be X = Y (tolerance: X Y
0.04 k) by slightly turning the potentiometer
body.
(Loosen screws (1) before adjusting)
5. Secure the potentiometer in place by tightening
screw (1).
Table 1
POTENTIOMETER No.
1
2
3
4
ST1
ST2
FR3
FR4
20-155-1
4
5V
A
M
L
O
PIN No.
SIG
GND
H
G
E
F
K
J
P
Q
D375A-5
Related electrical circuit diagram
D375A-5
20-155-2
4
CHECKING THE ADJUSTMENT OF PCCS LEVER

1. Install the pre-adjusted PCCS lever to the machine.
(For details, see DISASSEMBLY OF PCCS LEVER.)
2. Position PCCS lever in NEUTRAL (both forward & reverse, steering)
3. Turn key switch ON.
4. Check the voltage of each potentiometer (ST1, 2 & FR3, 4) by using the monitoring mode of the monitor
panel.
(For details, see SPECIAL FUNCTION OF MONITOR PANEL EMMS.)
5. Voltage should be 2,500 50 mV for each potentiometer.
ADJUSTING IN ATTACHED CONDITION
2. Using tester (4), adjust voltage by turning potentiometer slightly, so that the voltage becomes 2.5 V.
3. Tighten screw (2) at the position of voltage 2.5 V, and fix the potentiometer (1).
1. Potentiometer
5. T-adapter
2. Screw
6. Controller
3. PCCS lever
7. Machine power source
4. Tester
8. External power source (5 V)
20-155-3
4
A. Wiring connection of adjustment for machine

power source.
B. Wiring connection of adjustment for external
power source.
D375A-5
DISASSEMBLY AND ASSEMBLY OF PCCS LEVER

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

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

(11).
9. Loosen screw (9), then adjust voltage by turning
potentiometer (10) slightly.
ASSEMBLY
For assembly, procedure in reverse order.
20-155-5
4
D375A-5

MAIN CONTROL VALVE
4. Blade lever at LEFT TILT
10-156
D375A-5

MAIN CONTROL VALVE
When the blade lever is moved to the LEFT TILT

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

moved to the end of its stroke, the hydraulic pressure in the whole circuit rises.
flows from port A2, and pushes open main relief
valve poppet (14). It is then relieved to port E2,
so the hydraulic pressure does not rise any further.
{210 kg/cm2}.
D375A-5
10-157

MAIN CONTROL VALVE
5. Ripper lever at TILT IN (ripper Lo valve, shuttle valve actuated)
10-158
D375A-5

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

MAIN CONTROL VALVE
6. Ripper lever at TILT IN (ripper Hi valve actuated)
10-160
D375A-5

MAIN CONTROL VALVE
As explained in item 5, the oil from the large

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

MAIN CONTROL VALVE
7. Ripper level at LOWER (ripper Lo valve, shuttle valve actuated)
10-162
D375A-5

MAIN CONTROL VALVE
When the ripper lever is moved to the LOWER

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

MAIN CONTROL VALVE
8. Blade lever at HOLD, ripper lever at LOWER (ripper Hi valve actuated)
10-164
D375A-5

MAIN CONTROL VALVE
As explained in item 7, the oil from the large

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

MAIN CONTROL VALVE
9. Ripper lever at LOWER (cylinder at stroke end)
10-166
D375A-5

MAIN CONTROL VALVE
From the condition in items 7 and 8. if cylinder

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

CYLINDER STAY
CYLINDER STAY
1.
2.
3.
4.
Yoke
Oil seal
Bushing
Bushing
Unit: mm
No.
Check item
Criteria
Tolerance
Shaft
Hole
Standard
clearance
Clearance
limit
150
0.085
0.148
+0.063
0
0.085
0.211
0.5
Clearance between cylinder yoke

and bushing
115
0.072
0.126
+0.054
0
0.072
0.180
0.5
Clearance between lift cylinder

support shaft and bushing
105
0.120
0.207
+0.035
0
0.120
0.242
0.5
Clearance between cylinder yoke

and bushing
10-168
Standard
size
Remedy
Replace
D375A-5

BLADE
BLADE
SEM-U DOZER
10-170
D375A-5

BLADE
Unit: mm
No.
Check item
Clearance between brace pin and

brace
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
Shaft
Hole
75
0.2
0.3
+0.3
+0.1
0.3 0.6

bracket
75
0.2
0.3
+0.3
+0.1
0.3 0.6

bracket
75
0.2
0.3
+0.3
0
0.2 0.6

bushing
75
0.2
0.3
+0.2
0
0.2 0.5
Clearance between center brace

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

bracket
200
0.2
0.7
+0.3
+0.1
0.3 1.0
Clearance between frame pin and

joint
100
0.3
0.5
+0.3
0
0.3 0.8

joint
100
0.3
0.5
+0.5
+0.2
0.5 1.0
Clearance between straight

frame joint bushings
160
0.3 0.4
10
Clearance between trunnion and

cap spherical surface
200
0.5
1.0
+0.5
0
0.5 1.5
11

bracket
200
0.2
0.7
+0.3
+0.1
0.3 1.0
12
Clearance between blade pin and

joint
100
0.3
0.5
+0.3
0
0.3 0.8
13

bracket
100
0.3
0.5
+0.5
+0.2
0.5 1.0
14
Clearance between center link

pin and blade bracket
125
0.3
0.5
+0.5
+0.2
0.5 1.0
15

pin and center link
125
0.3
0.5
+0.5
+0.2
0.5 1.0
16

and blade bracket
280
0.2
0.4
+0.3
+0.1
0.3 0.7
17

spherical surface and cap
170
0.2
0.3
+0.3
0
0.2 0.6
D375A-5
Replace
Adjust shim or
replace
Replace
Adjust shim or
replace
10-171

BLADE
U-DOZER
10-172
D375A-5

BLADE
Unit: mm
No.
Check item

brace
Criteria
Standard
size
Tolerance
Remedy
Standard
clearance
Clearance
limit
Shaft
Hole
75
0.2
0.3
+0.3
+0.1
0.3 0.6

bracket
75
0.2
0.3
+0.3
+0.1
0.3 0.6

bracket
75
0.2
0.3
+0.3
0
0.2 0.6

bushing
75
0.2
0.3
+0.2
0
0.2 0.5

and cap spherical surface
170
0.2
0.3
+0.3
0
0.2 0.6

bracket
200
0.2
0.7
+0.3
+0.1
0.3 1.0

joint
100
0.3
0.5
+0.3
0
0.3 0.8

bracket
100
0.3
0.5
+0.5
+0.2
0.5 1.0
Clearance between straight

frame joint bushings
160
0.3 0.4
10
Clearance between trunnion and

cap spherical surface
200
0.5
1.0
+0.5
0
0.5 1.5
11

bracket
200
0.2
0.7
+0.3
+0.1
0.3 1.0
12

joint
100
0.3
0.5
+0.3
0
0.3 0.8
13

bracket
100
0.3
0.5
+0.5
+0.2
0.5 1.0
14

pin and blade bracket
125
0.3
0.5
+0.5
+0.2
0.5 1.0
15

pin and center link
125
0.3
0.5
+0.5
+0.2
0.5 1.0
16

and blade bracket
280
0.2
0.4
+0.3
+0.1
0.3 0.7
17

spherical surface and cap
170
0.2
0.3
+0.3
0
0.2 0.6
D375A-5
Replace
Adjust shim or
replace
Replace
Adjust shim or
replace
10-173

BLADE
CUTTING EDGE, END BIT
Unit: mm
No.
Check item
Criteria
Remedy
Standard size
Repair limit
478
380
Width of end bit
734
600
Height of end bit inside
393
300
Height of cutting edge
406
335 (264 after turned)
Height of end bit outside
10-174
Replace
Replace or turn
D375A-5

RIPPER EQUIPMENT
RIPPER EQUIPMENT
VARIABLE MULTIPLE SHANK RIPPER
10-176
D375A-5

RIPPER EQUIPMENT
GIANT RIPPER
Unit: mm
No.
Check item
Clearance between bushing and

bracket and arm mount pin
Criteria
Standard
size
Tolerance
Remedy
Shaft
Hole
Standard
clearance
Clearence
limit
120
0.036
0.090
+0.208
+0.125
0.161
0.298
1.5
Clearance between bushing and

beam and arm mount pin
120
0.036
0.090
+0.208
+0.125
0.161
0.298
1.5
Clearance between cylinder

mount pin and bushing
100
0.036
0.090
+0.207
+0.120
0.156
0.207
1.5
Clearance between shank and

mount pin
Wear of point
Wear of protector
D375A-5
Standard size
Tolerance
Repair limit
82
0.3
Standard size
Repair limit
420
255
155
115
Replace
10-177

CAB MOUNT
CAB MOUNT
1. Support
2. Damper mount (Front)
3. Damper mount (Rear)
Outline
10-178
The cab mount is installed at two places in the

front and at two places in the rear, and the floor
frame and the cab are secured.
The cab mount adopts an oil seal type damper
mount and absorbs vibration.
D375A-5

CAB
CAB
CAB ASEMBLY
1.
2.
3.
4.
Front wiper
Front glass
Rear wiper
Door
D375A-5
10-179

CAB
ROPS GUARD
1. ROPS guard
10-180
D375A-5

AIR CONDITIONER
AIR CONDITIONER
AIR CONDITIONER PIPING
1.
2.
3.
4.
5.
6.
7.
8.
9.
Air conditioner compressor

Window defroster
Side defroster
Air conditioner unit
Blower port
Blower motor
Hot water pick-up piping
Condenser
Receiver tank
D375A-5
10.
11.
12.
13.
Valve (hot water outlet)

Hot water return piping
Valve (hot water inlet)
Refrigerant piping
A. Fresh air
B. Recirculated air
C. Hot air/cold air
10-181

ENGINE CONTROL
ENGINE CONTROL
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Decelerator pedal
Starter switch
Decelerator potentiometer
Steering controller
Transmission controller
Fuel throttle dial
Battery
Battery relay
Starter
Engine controller
Fuel pump
10-182
Outline
The throttle signal of the throttle dial enters the

steering controller and the transmission controller and is processed together with another information, then sent to the engine controller as a
throttle command. The engine controller controls
the control valve unit and the fuel pump in accordance with the command.
D375A-5

ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM
Outline
The engine controller receives the manual signal

of the second throttle and the third throttle signal
that is the control signal from a vehicle body and
selects a low engine speed, then controls the
control valve unit.
The third throttle control signal includes the following items:
1 First throttle signal
2 SSC (Shoe Slip Control) control
3 Auto decelerators (F3, R3, R2)
The engine control system shares the information about the engine controller with another controller through networks and contributes to the
optimum control between the engine and the vehicle body.
As the auto decelerator function, the engine
speed is temporarily set to 1,000 rpm when forward and reverse from F3, R3, and R2 are
switched. (For transmission clutch protection)
The steering controller selects the lowest engine

speed from the information 1, 2, and 3 and
sends it to the engine controller as the third throttle.
D375A-5
10-183

DECELERATOR POTENTIOMETER
DECELERATOR POTENTIOMETER
1.
2.
3.
4.
5.
6.
7.
Connector
Lever
Body
Potentiometer
Coupling
Shaft
Stopper
10-184
Outline
The decelerator potentiometer is mounted on

the lower front of the operator cab and connected with the decelerator pedal using a linkage.
When the decelerator pedal is actuated, the

shaft of the throttle potentiometer rotates via the
linkage and a resistance value is changed.
Fixed voltage is applied between the pins A to C
of the potentiometer and a voltage signal that
matches the actuation position of the decelerator
pedal is sent from the B pin to the engine controller.
D375A-5

HPI ENGINE CONTROL SYSTEM

HPI is an abbreviation of High Pressure Injection.
System drawing
Outline
The signals detected by various sensors are input to the engine controller.
The input signals are operated arithmetically by
the controller. A signal is issued to each actuator
and controls a fuel injection level and fuel injection timing.
10-186
D375A-5

1. Fuel tank
2. Fuel filter
3. Fuel pump assembly
3A. Gear pump
3B. Pump regulator
3C. Check valve
3D. Fuel pump actuator
3E. Fuel pump pressure sensor
4. Control valve assembly
4A. Timing rail actuator valve
4B. Fuel leak throttle (220 cc/min)
4C. Timing rail pressure sensor
4D. Shut-off valve
4E. Fuel rail actuator valve
4F. Fuel leak throttle (110 cc/min)
4G. Fuel rail pressure sensor
5. Injector assembly
5A. Timing orifice
5B. Fuel orifice
5C. Gravity check valve
5D. Bypass orifice
5E. Injector
5F. Plunger
5G. Gravity check valve
6. Fuel cooler
7. ECM controller
8. Engine speed sensor
9. Atmospheric pressure sensor
10. Boost pressure sensor
11. Boost temperature sensor
D375A-5
OUTLINE OF HPI SYSTEM
The HPI system consists of injector assembly

(5), control valve assembly (4), and fuel pump
assembly (3).
Injector assembly (5) controls the amount of fuel
injection and the injection timing by controlling
the amount of fuel passing through fuel orifice
(5B).
In order to control the fuel flow, it is necessary to
control the fuel rail pressure and timig rail pressure. To control these pressures, control valve
assembly (4) has 2 pressure sensors and 2 actuator valves built in. These carry out control so
that the fuel rail rail pressure and timing rail pressure become the target value. Shut-off valve
(4D), used to stop the engine, is installed in the
fuel rail line.
Fuel pump assembly controls the basic pressure
of the fuel. The fuel supplied from fuel tank (1)
passes through fuel filter (2), is then sucked up
by gear pump (3A), and is supplied to control
valve assembly (4). The discharge pressure of
the fuel pump is controlled to a suitable level by
adjusting the opening angle of fuel pump actuator (3D).
10-187

MONITOR SYSTEM
MONITOR SYSTEM
The monitor system monitors the state of the vehicle by the sensor mounted on each portion of
the vehicle and quickly processes the information, then displays it on the panel, thereby reporting the state of the vehicle to the operator.
The contents displayed on the panel are roughly
divided as follows:
1. Monitor portion that issues an alarm when
an error occurred in the vehicle.
2. Gauge portion (coolant temperature, torque
converter oil temperature, fuel level) that always displays the state.
3. Function that displays error codes.
4. Function that monitors current and voltage
values of each sensor and solenoid.
10-188
Further, the monitor panel incorporates the various mode selection switches of the SSC (shoe
slip control) and has the function of the control
portion of the vehicle control system.
The monitor panel has the monitor display function and the switch function for the SSC mode
selection.
A CPU (central processing unit) is installed inside. The CPU processes information and displays and outputs it. The CPU uses an LCD as
the monitor display portion. Further, the switch is
a flat sheet switch.
D375A-5

MONITOR SYSTEM
Monitor Panel Processing (All Specifications)

Monitor panel display
1 Processing contents and condition
2 System
3 Flow of signal
1) Display of forward-reverse, number of gear S-NET communication Transmission controller Steering

controller Monitor panel
ratios
F1 and R3 are reported by S-NET based on
the information about the transmission controller.
S-NET communication Engine speed sensor Engine
2) Gauge display of engine speed
controller Steering controller
The pulse of the engine speed sensor is
Monitor panel
substituted for the number of gauges and
the number of gauges is reported to the
monitor panel by S-NET.
S-NET communication Each sensor, solenoid Controller
3) Troubleshooting display
Monitor panel
At fault, the relevant failure code is reported
to the monitor panel by S-NET.
The information as to whether the buzzer
sounds or the caution lamp comes on according to the failure contents is also reported.
1 At normal time
User codes
2 In failure history display mode
Service codes
The monitor panel alternatively displays
codes and hour meter values on the hour
meter display portion.
Monitoring display
1 Processing contents and condition
2 System
3 Flow of signal
1) The communication states of each sensor, S-NET communication Each sensor Controller Monitor panel
each solenoid, and S-NET are displayed.
An item number and an equipment state are
reported to the monitor panel by S-NET.
The monitor panel displays an item on the
speed display portion and the relevant value
on the hour meter portion.
2) An item advances by the reverse slow button of the monitor panel.
The item returns by the buzzer cancel
switch.
D375A-5
Monitor panel Controller Monitor panel
10-189

MONITOR PANEL
MONITOR PANEL
Monitor portion
1.
2.
3.
4.
5.
6.
7.
Display plate (Speed range display)

Power train oil temperature gauge
Engine water temperature gauge
Charge lamp
Fuel thermometer gauge
Engine oil pressure caution lamp
Engine water temperature caution lamp
Outline
The monitor portion consists of a monitor that issues an alarm when an error occurred in a vehicle, a gauge that always displays the state of the
vehicle, and the service meter.
The monitor portion installs a microcomputer
and processes and displays signals from each
sensor.
Besides, the items displayed on the monitor portion and gauge portion are listed in the table on
the next page.
Operation
1. When the power turns on (When the starter
switch is ON)
1) All items of the gauge and monitor portions
come on for three seconds.
2) The alarm lamp comes on for two seconds.
8.
9.
10.
11.
12.
13.
14.
Power train oil temperature caution lamp

Hydraulic oil temperature caution lamp
Preheat pilot lamp
Dual tilt display lamp
Radiator water level check lamp
Fuel gauge
Service meter
2) Start-up inspection items comes off when
the engine starts.
(Whether the engine is operating or not is
decided depending on whether the engine oil
pressure is raised or the voltage from the alternator exceeds 10 V.)
3. Cautions
Caution items are checked until the engine stops
after the engine starts.
If an error occurs, the error is displayed by flashing and the alarm lamp synchronously flashs.
Further, if an emergency item flashs, the alarm
buzzer also sounds synchronously.
Flashing of the monitor and alarm lamp is repeated. They come on and off for about 0.8 second.
The flashing period of the monitor slightly changes when atmospheric temperature is low (below
about 10C), but this case is not abnormal.
2. Start-up inspection
1) After all lighting of Section 1 is terminated, if
there is an error in a start-up inspection item,
the item flashs.
10-190
D375A-5

MONITOR PANEL
Monitor Panel Display

Category
Symbol
Display item
Display range
Display method
The monitor panel is displayed when the
engine is stopped and the starter switch
is ON.
For the display, the monitor panel comes
off at normal time and flashes at abnormal time.
Radiator water level
Below low level
Engine oil pressure

At sensor error or haroff at normal time and flashes at abnorness disconnection
mal time.
Charge level
At faulty charge
Engine oil pressure
49.0 kPa {0.5 kg/cm2}

or less
Below low level
SAP00522
When the start switch is ON and the engine is rotating, the monitor panel is displayed.
off at normal time and flashes at abnormal time.
At the same time, the alarm lamp flashes.
When the start switch is ON and the engine is rotating, the monitor panel is disWhen the engine coolplayed.
ant temperature
Engine coolant temperFor the display, the monitor panel comes
gauge is in the maxiature
off at normal time and flashes at abnormum level (108C or
mal time.
more)
At the same time, the alarm lamp flashWhen the torque con- es and the alarm buzzer sounds.
Torque converter oil
verter oil temperature
temperature
is in the maximum level (130C or more)
Hydraulic oil temperature
Preheat
D375A-5
103 3C or higher
Preheat time
When the atmospheric temperature is

below about 5C, the switch panel
comes on for 36 seconds with the sheet
switch (ENGINE HEAT) ON. Subsequently, it flashes for 16 seconds and
displays the completion of preheat.
10-191

Category
Symbol
MONITOR PANEL
Display item
Display range
Display method
Engine coolant temperature
The relevant one place comes

on.

temperature
All places come on below the relevant level.
Fuel level
Time meter
10-192
0 to 99,999 hours
Actuated when the alternator is

charged.
D375A-5

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

In a field, such as a rock-bed place where many shoe
slips are generated, the following power is output in
each mode so that the frequency of decelerator operation can decrease.
Economy mode 1 Set to about 90% of the full
power.
Economy mode 2 Set to about 70% of the full
power.
Reverse slow mode Set to about 80% of the
full travel speed at reverse time.
D375A-5
2. Initial Setup at key ON

The function the operator desires according to
the situation of an operating place is selected
and all functions shall be set to the OFF state.
10-193

SENSORS
SENSORS
Sensor and type
Sensor system
Normal time
Abnormal time
Engine oil pressure
Contact
OFF
ON
Engine water temperature
Resistor

temperature
Resistor
Contact
ON
OFF
Contact
ON
OFF
Fuel level
Resistor
Engine oil pressure sensor
1.
2.
3.
4.
5.
6.
Plug
Contact ring
Contact
Diaphragm
Spring
Terminal
10-194
D375A-5

SENSORS
Engine Water Temperature Sensor

Torque converter oil temperature sensor
1. Thermistor
2. Body
3. Tube
4. Tube
5. Wire
6. Connector
Hydraulic oil temperature sensor
1. Switch
2. Plug
3. Tube
4. Wire
5. Connector
Radiator water level sensor
1. Float
2. Sensor
3. Tube
D375A-5
4. Wire
5. Connector
10-195

SENSORS
Fuel level sensor
1.
2.
3.
4.
5.
6.
7.
Connector
Float
Arm
Body
Spring
Contact
Spacer
10-196
Function
The fuel level sensor is installed to the bottom

right of the front face of the fuel tank.
Float (2) moves up and down according to the
fuel level. This movement of the float is transmitted by arm (3) and actuates a variable resistance. This sends a signal to the monitor panel
to indicate the remaining fuel level. When the
display on the monitor panel reaches a certain
level, a warning lamp flashes.
D375A-5

MODE SELECTION SYSTEM

(SSC (Shoe slip control) system)
System drawing
Outline
The mode selection system automatically performs the engine control that matches the work
condition selected by the operator. It reduces a
fuel cost, makes the life of the track longer, and
reduces the frequency of decelerator operation.
The engine control mode includes the economy
mode control used at dozing time, the SSC used
at ripping time, and the reverse slow mode control that can be used in both.
D375A-5
The lock-up control mode is the same mode as

the conventional lock-up function and cannot
perform simultaneous selection with the above
mode.
10-197

Mode selection function
This system comprises the mode selection panel

(with a built-in microcomputer) for the operation
mode selection, steering controller (with a builtin microcomputer) for the engine control and the
engine controller that, responding to the instruction from the steering controller, implements the
actual control by use of the control valve. The
system also comprises the transmission controller that turns on or off the torque converter lockup responding to the signal from the transmission output speed sensor plus various types of
sensors.
Following describes the functions of respective
controllers.
4. The transmission controller sends the lock-up

signal to the lock-up solenoid valve. The applicable lock-up signal is decided based the entered
gear speed information of the transmission controller.
Refer to the Operation of Torque Converter
Lock-up Control System.
Functions of the engine controller

1. The engine controller controls the control valve
unit responding to the manual instruction entered from the deceleration potentiometer or the
SSC instruction whichever designates a slower
engine speed (a higher voltage).
Functions of the steering controller and

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

Operation of mode selection system
Work can be performed under the optimum conditions by simply or simultaneously selecting five modes in
accordance with the contents of work.
Work
Mode Single Simultaneous

switch selection selection
Mode work condition

ON/OFF switching is automatically performed in accordance with a load.
Speed number
of gear ratios
ON
1,230 rpm
or more
F2, F3
R1, R2, R3
1,260 rpm
or more
OFF
1,200 rpm
or more
1,230 rpm
or more
ON
2,140 rpm
or more
OFF
F1
Mode operation, characteristic

1. When the torque converter approaches to the
stall area or performs gear shaft operation,
lock-up is set to OFF. When the torque converter reaches a light lode, lock-up is set to ON.
2. Can be used in all number of gear ratios.
3. Simultaneous selection disabled with another
mode
4. Suitable for dozing work of comparatively a few
load fluctuations
2,200 rpm
or more
1. When F1 is shifted with the economy 1. When the economy mode (1 or 2) and SSC
mode switch 1 or 2 ON
are set simultaneously, the F1 shift economy
control is performed. When the ripper lever is
actuated and the switch is turned on, the slip
control is performed.
2. The engine output can be suppressed in two
stages without performing the decelerator operation of the engine.
Mode 1: 90% (at 1.5 km/h)
Mode 2: 65% (at 1.5 km/h)
3. At neutral time, the engine speed can be suppressed partially
1. When R1, R2, and R3 are shifted
1. The engine speed can be suppressed without

performing the decelerator operation of the engine.
2. Target travel speed at reverse time
R1
R2
70% at full operation
R3
The following conditions are satisfied:

1. At start, to prevent rashing out, the modulating
valve is actuated. At this time, the steering con1 When F1 is shifted.
troller performs index characteristic down of
2 After the ripper down, ripper tilt levers are
about 40% and performs the engine outpuut
actuated and the switch is set to ON
control if a ripper down signal is input.
2. The seering controller performs the engine output control in accordance with the index force
characteristic (refer to the rock-bed selection
shown below) selected by the operator among
the index force characteristics set in five stages
and suppresses the generation of a slip.
3. The steering controller regards the index force
immediately before the slip (exceeding the
shoe ripping ratio of 30% is generated, as the
maximum, and performs the engine output
control. At this time, the steering controller performs index characteristic down of about 30 to
80% and performs the engine outpuut control if
a ripper tilt or ripper up signal is input.
4. At neutral time, the engine speed is suppressed partially.
Set to ON in connection with SSC
1. When the SSC is set to ON, the selection mode

3 comes on.
2. 1 3 5 is selected in accordance with the
state and load of the rock-bed.
When the above mode is set, the throttle lever and decelerator operations are enabled. In that case, the engine
output control is performed in accordance with the command having the smallest value among the control command, throttle command, and decelerator command.
D375A-5
10-199

SENSORS
SENSORS
Engine speed sensor
Transmission output shaft speed sensor
1.
2.
3.
4.
5.
Magnet
Terminal
Case
Boots
Connector
10-200
D375A-5

SENSORS
Acceleration sensor
1. Sensor portion
2. Wire
3. Connector
Outline
The acceleration sensor is mounted at the lower

front of the operator cab.
The acceleration sensor changes the position of
a ball inside the sensor in accordance with acceleration.
The coil that detects the position of this ball is
provided inside the sensor. This is amplified by
an amplifier to change voltage and the result is
sent to the SSC controller.
Refer to the drawing at the right for the sensor input/output chatacteristics.
D375A-5
10-201

SENSORS
Pitch angle sensor
1.
2.
3.
4.
Body
Tube
Wire
Connector
10-202
D375A-5

ELECTRICAL DEVICE
ELECTRICAL DEVICE
Relay box
D375A-5
10-203

ELECTRICAL DEVICE
OPERATION OF LAMP SYSTEM
ELECTRICAL CIRCUIT OF LAMP SYSTEM
10-204
D375A-5

ELECTRICAL DEVICE
OPERATION OF ELECTRICAL INTAKE AIR HEATER
ELECTRCAL CIRCUIT OF PREHEATING
D375A-5
10-205

STEERING ELECTRONIC CONTROL
1.
2.
3.
4.
5.
Monitor panel (Speed range display)

Auto shift down switch
Engine controller
Steering controller
10-206
6.
7.
8.
9.

Transmission output shaft speed sensor
Transmission control valve
Engine speed sensor
D375A-5

Shift Mode Function
1. Function
If you shift the lever to the forward or reverse, the
gear speed selected from the shift mode is
turned on.
A: Shift mode 1
B: Shift mode 2
2. Type of Modes
1 F1-R2
2 F2-R2A
3 F1-R1 (Manual mode)
Shift the steering or forward-reverse lever to N.
3. Selecting method
Shift up switch ON
Manual mode
Shit up switch ON
Shift mode 1
Shift down switch ON
Shift mode 2
Shift down switch ON
4. Displaying method
Monitor panel
Auto Shift-down Function
1. Operating condition
This function automatically shifts the gear speed
down if load is increased while the machine is
travelling at 2nd or 3rd speed or while the machine is in operation.
2. Selecting method
Turn the auto shift-down switch (1) ON.
3. Operation and features of the mode
1) This function turns on the shift-down automatically by calculating the drawbar pull
(load to the machine body) based the engine
speed, transmission speed and throttle information from the steering controller.
2) Once the machine is automatically shifted
down, shit-up wont be turned on automatically (shift up from the manual switch is available, though).
3) This function is available for both the forward
and reverse travel.
D375A-5
10-207
20 TESTING AND ADJUSTING

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

Engine unit
Machine model
D375A-5
Engine
Engine
Item
Engine speed
High idling
Low idling
Rated speed
Air supply
(boost pressure)
At rated output
Exhaust temperature
Whole speed range

(ambient temperature: 20C)
Exhaust gas color
At sudden acceleration
At high idling
Valve clearance
Intake valve
(normal temperature) Exhaust valve
SA6D170E-3
Unit
Standard value for new

machine
Service limit value
rpm
1,900 30
720 30
1,800
1,900 30
720 30
1,800
kPa
{mmHg}
Min. 107 {Min. 800}
93{700}
Max. 680
700
Bosch
index
Max. 4.0
Max. 1.0
6.0
2.0
mm
Max. 0.32
Max. 0.62
Max. 0.32
Max. 0.62
MPa
{kg/cm2}
(rpm)
Min. 2.9 {Min. 30}

(210 - 250)
2.1{21}
(210 - 250)
Max. 4.9 {Min. 500}
7.9{800}
0.38 - 0.59{4.0 - 6.0}

0.34 - 0.54{3.5 - 5.5}
0.21{2.1}
0.18{1.8}
Min. 0.12 {Min. 1.2}

Min. 0.10{Min. 1.0}
0.07{0.7}
0.05{0.5}
Compression pressure
Oil temperature: 40 - 60C

(engine speed)
Blow-by pressure
Water temperature: Within operating

range
At rated output
kPa
{mmH2O}
Oil pressure
Water temperature: Within operating

range
At high idling
SAE30 or SAE15W-40 oil
SAE10W oil
At low idling
SAE30 or SAE15W-40 oil
SAE10W oil
MPa
{kg/cm2}
Oil temperature
Whole speed range (inside oil pan)
90 - 110
120
Fan belt tension
Deflection when pressed with finger

force of approx. 58.8 N {6 kg}
mm
Auto tension
Auto tension
Alternator, air conditioner compressor

belt tension
Deflection when pressed with finger

force of approx. 98 N {10 kg}
mm
New part: 19 - 21
When adjusting
tension: 24 - 26
When measuring the low idling speed after reducing speed suddenly from high speed, wait for several seconds for the speed to stabilize before measuring.
20-2
(5)
1
D375A-5
20-2 TESTING AND ADJUSTING


HPI control devices
Name of
component
Atmospheric
pressure sensor
Boost pressure
sensor
Intake air
temperature
sensor
Oil pressure
sensor
D375A-5
Connector Inspection
No.
method
Judgment table
Measurement
conditions
AAPR
If the condition is as shown in the table below, it is normal 1) Connect T-adapter

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

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

switch OFF.
Intake air
2) Disconnect conPin
Resistance
temperature
nector.
0C
30 k 36 kz
25C
9 k 11 kz
Between (A) and (B)
50C
3 k 4 kz
75C
1,350 1,500 z
100C
600 675 z
Between (A), (B)
Min. 1 Mz
and ground
OPS

to connector.
Pin
Oil pressure
Voltage
2) Turn starting
Between (A) and (B)
4.75 5.25 V
switch ON.
0 kPa
0.5 0.08 V
{0 kg/cm2}
Between (C) and (B)
689 kPa
4.5 0.08 V
{7.03 kg/cm2}
20-2-1
(5)
Name of
component
Fuel temperature
sensor
Water
temperature
sensor
Engine speed
sensor
Fuel pump
pressure sensor
Fuel rail pressure

sensor
20-2-2
(5)
No.
method
Judgment table
Measurement
conditions
FLTP

switch OFF.
Fuel
Resistance
temperature
nector.
0C
30 k 36 kz
25C
9 k 11 kz
Between (A) and (B)
50C
3 k 4 kz
75C
1,350 1,500 z
100C
600 675 z
Between (A), (B)
Min. 1 Mz
and ground
CLTP

switch OFF.
Water
Resistance
temperature
nector.
0C
30 k 36 kz
25C
9 k 11 kz
Between (A) and (B)
50C
3 k 4 kz
75C
1,350 1,500 z
100C
600 675 z
Between (A), (B)
Min. 1 Mz
and ground
SP1
SP2

switch OFF.
Pin
Resistance
2) Disconnect conBetween (A) and (B)
1,000 2,000 z
nector.
Between (A) (B) and ground
Min. 1 Mz
PMPR

to connector.
Pin
Fuel pressure
Voltage
2) Turn starting
Between (A) and (B)
4.75 5.25 V
switch ON.
0 kPa
0.5 0.04 V
{0 kg/cm2}
Between (C) and (B)
2,582 kPa
4.5 0.06 V
{26.33 kg/cm2}
RPR

to connector.
Pin
Fuel pressure
Voltage
2) Turn starting
Between (A) and (B)
4.75 5.25 V
switch ON.
103 kPa
0.5 0.04 V
{10.5 kg/cm2}
Between (C) and (B)
1,722 kPa
4.5 0.06 V
{17.56 kg/cm2}
D375A-5
Name of
component
Timing rail
pressure sensor
Fuel pump
actuator
Fuel shut-off
valve
Fuel rail actuator
Timing rail
actuator
D375A-5
No.
method
TPR
Judgment table
Measurement
conditions

to connector.
Pin
Fuel pressure
Voltage
2) Turn starting
Between (A) and (B)
4.75 5.25 V
switch ON.
0 kPa
0.5 0.04 V
{0 kg/cm2}
Between (C) and (B)
2,582 kPa
4.5 0.06 V
{26.33 kg/cm2}
PUMP

switch OFF.
Pin
Resistance
2) Disconnect conBetween (A) and (C)
79z
nector.
Between (A) (C) and ground
Min. 1 Mz
FSO+
FSO

switch OFF.
Pin
Resistance
2) Disconnect conBetween FSO+ and FSO
23 40 z
nector.
Between FSO+, FSO and ground
Min. 1 Mz
RAIL

switch OFF.
Pin
Resistance
79z
nector.
Min. 1 Mz
TIMG

switch OFF.
Pin
Resistance
79z
nector.
Min. 1 Mz
20-2-3
(5)
STANDARD VALUE TABLE FOR MACHINE RELATED PARTS

Machine model
Engine
Item
D375A-5
Measurement conditions
Unit
900 50
900 50
1,430
1,300 60
1,160
Neutral
FORWARD
30 5
Max. 8.0
Neutral
REVERSE
30 5
30 5
40 5
(Play: Max. 3)
40 5
(Play: Max. 3)
95
95
45 15
45 15
75 10
75 10
75 10
75 10
72 10
72 10
53 10
53 10
78 10
78 10
81 10
81 10
Neutral !
FORWARD
53.9 9.8
{5.5 1.0}
53.9 9.8
{5.5 1.0}
Neutral !
REVERSE
53.9 9.8
{5.5 1.0}
53.9 9.8
{5.5 1.0}
Until clutch is
completely disengaged
14.7 4.9
{1.5 0.5}
14.7 4.9
{1.5 0.5}
26.5 4.9
{1.5 0.5}
26.5 4.9
{1.5 0.5}
Until clutch is
16.7 4.9
{1.7 0.5}
16.7 4.9
{1.7 0.5}
Until brake
takes effect and
machine turns
29.4 4.9
{3.0 0.5}
29.4 4.9
{3.0 0.5}
49.0 9.8
{5.0 1.0}
49.0 9.8
{5.0 1.0}
Engine water temperature: Within operating

range
Torque converter oil temperature: Within operating range
Hydraulic
oil temperature: 45 - 55C
Torque converter stall
+ work equipment re- Deceleration speed: Pedal depressed
Torque converter stall speed: F3
lief speed
Torque converter stall + work equipment
speed: F3 + ripper RAISE
Direction
Full stroke (Neutral - Left, right)

Steering
Deceleration pedal
Engine stopped
Center of lever knob
Brake pedal
Blade lever
Ripper lever
Direction
D375A-5
mm
mm
Full stroke
Stroke until oil
pressure becomes 0
mm
Engine at low idling

HOLD - RAISE,
Hydraulic oil temperature:
FLOAT
45 - 55C
HOLD - Left,
right tilt
mm

HOLD - RAISE,
LOWER
45 - 55C
HOLD - Tilt in,
tilt out
mm
Engine stopped
Until brake
takes effect and
machine turns
Steering
Deceleration pedal
rpm
Until clutch is

Engine stopped
Center of pedal
Service limit
value
1,520 50
Deceleration speed
Engine stopped
Standard value for

new machine
N
{kg}
N
{kg}
20-3
4
1
Machine model
Engine
Item
Control lever, pedal operating effort
Brake pedal
Blade lever
D375A-5
Unit
Standard value for

new machine
Service limit
value
N
{kg}
460.6 49.0
{47.0 5.0}
460.6 49.0
{47.0 5.0}
39.2 4.9
{4.0 0.5}
39.2 4.9
{4.0 0.5}
83.3 9.8
{8.5 1.0}
83.3 9.8
{8.5 1.0}
28.4 4.9
{2.9 0.5}
28.4 4.9
{2.9 0.5}
21.6 4.9
{2.2 0.5}
21.6 4.9
{2.2 0.5}
20.6 4.9
{2.1 0.5}
20.6 4.9
{2.1 0.5}
Low idling
0.03 0.15
{0.3 1.5}
0.03 0.15
{0.3 1.5}
High idling
0.9 0.10
{9.0 1.0}
0.9 0.10
{9.0 1.0}
Low idling
0.01 0.15
{0.1 1.5}
0.01 0.15
{0.1 1.5}
0.39 0.64
{4.0 6.5}
0.39 0.64
{4.0 6.5}
Low idling
High idling
1.27 1.47
{13.0 15.0}
1.27 1.47
{13.0 15.0}
Low idling
2.45 0.20
{25.0 2.0}
2.45 0.20
{25.0 2.0}
High idling
2.65 0.20
{27.0 2.0}
2.65 0.20
{27.0 2.0}
Low idling
2.55 0.15
{26.0 1.5}
2.35 2.94
{24.0 30.0}
High idling
2.70 0.15
{27.5 1.5}
2.45 2.94
{25.0 30.0}
2.55 0.15
{26.0 1.5}
2.35 2.94
{24.0 30.0}
High idling
2.70 0.15
{27.5 1.5}
2.45 2.94
{25.0 30.0}
Low idling
2.55 0.15
{26.0 1.5}
2.35 2.94
{24.0 30.0}
High idling
2.70 0.15
{27.5 1.5}
2.45 2.94
{25.0 30.0}
Center of pedal
Hydraulic oil temperature: 45 55C
HOLD
RAISE
HOLD
FLOAT
N
{kg}
HOLD
Left, right
tilt
Ripper lever
Torque converter inlet

pressure

Torque converter outlet

pressure
HOLD
RAISE,
LOWER
HOLD Tilt
in, tilt out
N
{kg}
High idling
Power train oil pressure
MPa
{kg/cm2}
Torque converter lockup clutch pressure
Torque converter stator clutch pressure
Transmission main relief pressure
Low idling
MPa
{kg/cm2}
Transmission F clutch
pressure
Transmission R clutch
pressure
20-4
D375A-5
Machine model
Engine
Item
Transmission 1st
clutch pressure
D375A-5
Power train oil pressure
Transmission lubrication pressure

Steering left brake

pressure
Steering right brake

pressure
Flat ground
range
Engine at high idling
Run-up distance: 10 - 30
m
Measuring distance: 20
m
When lock-up switch is OFF
Power train performance
D375A-5
2.25 0.2
{23.0 2.0}
1.96 2.55
{20.0 26.0}
High idling
2.25 0.2
{23.0 2.0}
1.96 2.55
{20.0 26.0}
Low idling
2.55 0.15
{26.0 1.5}
2.35 2.94
{24.0 30.0}
2.70 0.15
{27.5 1.5}
2.45 2.94
{25.0 30.0}
Low idling
2.55 0.15
{26.0 1.5}
2.35 2.94
{24.0 30.0}
High idling
2.70 0.15
{27.5 1.5}
2.45 2.94
{25.0 30.0}
High idling
0.20 0.05
{2.0 0.5}
0.20 0.05
{2.0 0.5}
Low idling
2.55 0.15
{26.0 1.5}
High idling
27.0 0.15
{27.5 1.5}
Min. 2.4
{Min. 24}
Min. 2.4
{Min. 24}
Low idling
2.50 0.15
{25.5 1.5}
Min. 2.4
{Min. 24}
High idling
2.65 0.15
{27.0 1.5}
MPa
{kg/cm 2}
High idling
27.0 0.15
{27.5 1.5}
Min. 2.4
{Min. 24}
Min. 2.4
{Min. 24}
Min. 2.4
{Min. 24}
Low idling
2.50 0.15
{25.5 1.5}
Min. 2.4
{Min. 24}
High idling
2.65 1.5
{27.0 1.5}
Low idling
Steering right clutch

pressure
Travel speed
Low idling
Unit
High idling
Transmission 3rd
clutch pressure
Pin puller actuation

pressure
Service limit
value
Transmission 2nd
clutch pressure
Steering left clutch

pressure
Standard value for

new machine
MPa
{kg/cm 2}
2.55 0.15
{26.0 1.5}
F1
18.9 1.0
(3.8 0.2)
Min. 2.4
{Min. 24}
Min. 2.2
{Min. 22}
18.9 1.0
(3.8 0.2)
F2
10.6 0.6
(6.8 0.3)
10.6 0.6
(6.8 0.3)
F3
6.1 0.3
(11.8 0.6)
6.1 0.3
(11.8 0.6)
15.0 0.8
(4.8 0.2)
15.0 0.8
(4.8 0.2)
R2
8.3 0.4
(8.7 0.4)
8.3 0.4
(8.7 0.4)
R3
4.9 0.3
(14.7 0.7)
4.9 0.3
(14.7 0.7)
High idling
R1
MPa
{kg/cm 2}
Sec.
(km/h)
2.55 0.10
{26.0 2.0}
20-5
1
Machine model
Item
Travel speed
Blade lift relief pressure
D375A-5
Standard value for
new machine
Service limit
value
F1
18.9 1.0
{3.8 0.2}
18.9 1.0
{3.8 0.2}
F2
10.6 0.6
{6.8 0.3}
10.6 0.6
{6.8 0.3}
F3
6.1 0.3
{11.8 0.6}
6.1 0.3
{11.8 0.6}
R1
14.1 0.7
{5.1 0.3}
14.1 0.7
{5.1 0.3}
R2
7.8 0.4
{9.2 0.5}
7.8 0.4
{9.2 0.5}
R3
4.6 0.3
{15.8 0.8}
4.6 0.3
{15.8 0.8}
Flat ground
range
Run-up distance:
10 - 30 m
Measuring distance:
20 m
When lock-up switch is ON
Power train performance
Engine
Unit
Sec.
(km/h)

Low idling
45 - 55C
Cylinder at stroke end
Standard value measured with High idling
oil pressure gauge
Work equipment oil pressure
+0.98
Min. 19.6
{Min. 200}
Min. 18.6
{Min. 190}
+0.98
High idling
20.6 0
{210 +100 }
Min. 19.6
{Min. 200}
MPa
{kg/cm2}
+0.98
Low idling
19.6 0
{200 +100 }
Min. 18.6
{Min. 190}
+0.98
High idling
20.6 0
{210 +100 }
Min. 19.6
{Min. 200}
+0.98
Low idling
19.6 0
{200 +100 }
Min. 18.6
{Min. 190}
+0.98
High idling
20.6 0
{210 +100 }
Min. 19.6
{Min. 200}
18.6 20.6
{190 210}
Min. 17.6
{Min. 180}
19.6 21.6
{200 220}
Min. 18.6
{Min. 190}
18.6 20.6
{190 210}
Min. 17.6
{Min. 180}
19.6 21.6
{200 220}
Min. 18.6
{Min. 190}
Low idling
18.6 20.6
{190 210}
Min. 17.6
{Min. 180}
High idling
19.6 21.6
{200 220}
Min. 18.6
{Min. 190}
Low idling
18.6 20.6
{190 210}
Min. 17.6
{Min. 180}
High idling
19.6 21.6
{200 220}
Min. 18.6
{Min. 190}
Ripper tilt relief pressure

Low idling
45 - 55C
Cylinder at stroke end
Standard value measured with High idling
monitor panel
Blade tilt relief pressure

High idling
Ripper lift relief pressure
Ripper tilt relief pressure

20.6 0
{210 +100 }
+0.98
Low idling
1
3
Min. 18.6
{Min. 190}
19.6 0
{200 +100 }
Ripper lift relief pressure
20-6
+0.98
Low idling
Blade tilt relief pressure
Blade lift relief pressure
19.6 0
{200 +100 }
MPa
{kg/cm2}
D375A-5
Machine model
Item
D375A-5
Standard value for
new machine
Service limit
value
4.51 0.29
{46.0 3.0}
Min. 3.9
{Min. 40.0}
High idling
9 15
26
Low idling
3.5 4.5
High idling
1.1 1.6
1.1 1.6
Low idling
1.1 1.6
1.1 1.6
Low idling
10 15
17
High idling
45
Low idling
8 12
16
High idling
34
Control circuit oil pres- Hydraulic oil temperature: 45 - 55C

sure
Circuit oil pressure: Lever at HOLD
Output pressure: Lever at full stroke
PPC valve output pressure
RAISE
Work equipment
oil pressure
Engine
LOWER
Left tilt
Blade tilt
Hydraulic oil temperature: 45 - 55C
Blade: No load
Full left tilt - Full right tilt
Right tilt
Sec.
Left tilt
Work equipment speed

Blade: No load
Ground level - Max.
height
Work equipment
MPa
{kg/cm 2}
Sec.
Blade lift
Low idling
High idling
Blade dual tilt

Right tilt
Sec.
Blade: No load
Full left tilt - Full right tilt
D375A-5
Unit
Low idling
High idling
20-7
3
1
Machine model
Engine
Item
D375A-5
Standard value for
new machine
Service limit
value
Low idling
7 11
15
High idling
2.5 3.5
Low idling
23
23
High idling
23
23
Low idling
12 18
24
High idling
4.5 5.5
Low idling
8 12
16
High idling
34
Max. 8
12
Max. 1.8
2.0
Max. 1.0
1.5
Unit
Dump
Low idling
High idling
Blade pitch
Sec.
Back
RAISE
LOWER
Sec.
Blade: No load
Ground level - Max.
height
Sec.
Time lag
Ripper
Tilt back
Ripper tilt
Blade
1

3
High idling
Ripper lift

Blade: No load
Full tilt in - Full tilt out
20-8
Low idling
Tilt in
Work equipment

Blade: No load
Full dump - Full back
Low idling
45 - 55C
Lever at full stroke
Raise blade to maximum
height, then lower blade and
measure time taken from point High idling
where blade contacts ground to
point where idler comes off
ground
Low idling
45 - 55C
Lever at full stroke
Raise ripper to maximum
height, then lower ripper and
measure time taken from point High idling
where ripper contacts ground
to point where sprocket comes
off ground
Sec.
D375A-5
Machine model
Engine
Item
Blade lift
D375A-5
Unit
Standard value for

new machine
Service limit
value
mm
Max. 200/15 min
400/15 min
mm
Max. 50/5 min
100/5 min
mm
Max. 50/5 min
80/5 min
mm
Max. 80/15 min
160/15 min

Engine stopped
Hydraulic drift for 15 minutes at bottom edge
of blade (change in height h)

Engine stopped
Hydraulic drift for 5 minutes at center of idler
(change in height h)
Hydraulic drift
Work equipment
Hydraulic drift of
chassis (blade
lift)
Blade tilt

Engine stopped
Retraction h of tilt cylinder
Ripper lift

Engine stopped
Hydraulic drift for 15 minutes at tip of shank
(change in height h)
D375A-5
20-9
3
1
Machine model
Hydraulic drift
Item
20-10

1
3
Hydraulic drift of
chassis (ripper
lift)
Unit
Standard value for

new machine
Service limit
value
mm
Max. 30/5 min
60/5 min
Max. 3.0
12
Max. 3.6
12
Max. 3.2
12

Engine stopped
Hydraulic drift for 5 minutes at center of
sprocket (change in height h)
Oil leakage from cylinder
Work equipment
Engine
D375A-5

Blade tilt cylinder Hydraulic oil temperature: 45 - 55C
Measure oil leakage during 1 minute at cylinder relief
Ripper lift
cc/min
cylinder
Ripper tilt
cylinder
D375A-5
MEASURING ENGINE SPEED

Measure the engine speed under the following
condition.
range
1. Preparation work
Turn the starting switch ON and set the monitor
panel in the "Monitoring mode" to prepare for
measurement of the engine speed.
For the operating method, see "Special functions of monitor panel (EMMS)".
Monitoring code: 99 (Engine speed)
The engine speed is displayed on the service meter display section in 1 rpm.
3. Measuring high idling speed

1) Start the engine and set the fuel control dial
in the high idling position.
2) Set the PCCS lever and work equipment
control lever in neutral and measure the engine speed.
4. Measuring decelerator pedal speed
in the high idling position.
control lever in neutral and press the decelerator pedal and measure the engine speed.
5. Measuring torque converter stall speed
in the low idling position.
2) Press the brake pedal securely and set the
parking brake lever in the FREE position and
set the PCCS lever in the FORWARD and
3rd gear speed position.
Before going to the next step, check that
the upper display unit of the monitor panel is set in the normal display state and it
displays [F3].
Keep the steering unit in neutral.
3) Press the decelerator pedal and set the fuel
control dial in the high idling position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idling.
Keep pressing the brake pedal securely
and keep your right foot on the decelerator pedal for safety until the work is finished.
5) Just after the torque converter oil temperature gauge reads the top line of the green
range, return the direction of the PCCS lever
into neutral.
2. Measuring low idling speed

in the low idling position.
control lever in neutral and measure the engine speed.
When measuring the low idling speed after
lowering the engine speed sharply from the
high speed range, wait for several seconds
until the engine speed is stabilized.
20-102
(5)
1
D375A-5
6) Repeat above steps 2) - 5) 3 times.

7) Perform steps 2) - 4) again and measure the
engine speed about 5 seconds after the
torque conver ter oil temperature gauge
reads the top line of the green range.
After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the torque converter oil temperature with the engine at high idling.
6. Torque converter stall + Work equipment relief speed (Full stall speed)
in the low idling position and raise the ripper
to the stroke end.
2) Keep pressing the brake pedal securely and
set the parking brake lever in the FREE position and set the PCCS lever in the FORWARD and 3rd gear speed position.
Before going to the next step, check that
the upper display unit of the monitor panel is set in the normal display state and it
displays [F3].
Set the steering unit in neutral.
3) Press the decelerator pedal and set the fuel
control dial in the high idling position.
4) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idling.
Keep pressing the brake pedal securely
and keep your right foot on the decelerator pedal for safety until the work is finished.
D375A-5
5) Just after the torque converter oil temperature gauge reads the top line of the green
range, return the direction of the PCCS lever
into neutral.
6) Repeat above steps 2) - 5) 3 times.

7) Perform steps 2) - 4) again and relieve the
ripper in the raising direction and measure
the engine speed about 5 seconds after the
torque conver ter oil temperature gauge
reads the top line of the green range.
After finishing measurement, return the
direction of the PCCS lever into neutral
and lower the torque converter oil temperature with the engine at high idling.
20-103
1
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE)

Tools for measuring intake air pressure (boost
pressure)
Symbol
Part No.
799-201-2202
Part Name
Boost gauge kit
A nipple (quick coupler) is installed to the intake

air pressure (boost pressure) pickup port of the
Pm clinic specification machine.
Be careful not to touch any hot parts when removing or installing the measuring tools.
Measure the intake air pressure (boost pressure)
under the following conditions.
Coolant temperature: Within operating range
1. Open the engine left side cover.
2. Remove intake air pressure measurement plug
(1).
3. Fit nipple 1 of boost gauge kit A, then connect

gauge 2.
20-104
(5)
1
4. Run the engine at a mid-range speed or above to

bleed the oil from the hose.
Insert the connection of the hose and pressure gauge about half way, repeat the action
to open the self-seal portion at the hose end,
and bleed the oil.
If Pm kit (A) is available, the air bleed coupling (790-261-1130) inside the kit can be
used.
If there is oil inside the hose, the gauge will
not work, so always bleed the oil.
5. Run the engine at high idling to stall the torque
converter, and measure the intake air pressure
(boost pressure).
For details of the procedure for stalling the
t o r q u e c o n ve r t e r, s e e M E A S U R I N G
TORQUE CONVERTER STALL SPEED.
The intake air pressure (boost pressure)
should be measured with the engine running
at rated output. However, when measuring
in the field, a similar value can be obtained at
torque converter stall speed.

condition.
D375A-5
MEASURING EXHAUST TEMPERATURE

Tools for measuring exhaust temperature
Symbol
Part No.
799-101-1502
Part Name
Digital temperature gauge
Measuring instruments for exhaust temperature

(Pm clinic specification)
Since the exhaust temperature sensor is installed to the Pm clinic specification machine,
prepare an adapter connector to connect the exhaust temperature sensor and digital temperature gauge.
Symbol
Part No.
Part Name
799-101-1502
Digital temperature gauge
799-201-1150
Adapter connector
Wait for the manifold temperature to go down before removing or installing the measuring equipment.
Measure the exhaust temperature under the following conditions.
4. Procedure when measuring the maximum value

during troubleshooting
Carry out actual work and measure the maximum value during operation.
Use the PEAK mode of the digital temperature gauge.
The exhaust temperature varies greatly according to the ambient temperature (temperature of the engine intake air), so if any
abnormal value is obtained, carry out temperature compensation using the following
formula.
Compensation value [C] = Measured
value + 2 x (20 - ambient temperature)
1. Open the engine right side cover, then remove

the adiabatic cover.
2. Remove exhaust temperature measurement
plug (1).
3. Fit sensor 1 of digital temperature gauge B,

then connect to meter 2.
Clamp the wiring harness of the digital temperature gauge to prevent it from touching
any hot part during measurement.
D375A-5
5. Procedure when measuring periodically or during preventive maintenance

If only torque converter stall is used, the
power train oil temperature will overheat before the exhaust temperature stabilizes, so
always use the following procedure when
measuring.
1) Use the following procedure to carry out full
stall and raise the exhaust temperature to
approx. 650C. (Condition a in the diagram).
i) Start the engine, set the fuel control dial
to the low idling position, then operate
the ripper lever to move the ripper lift cylinder to the end of the RAISE stroke.
ii) Keep the brake pedal firmly depressed,
operate the PCCS lever to the F position
and set the speed to 3.
20-105
(5)
1
iii) Depress the decelerator pedal and set

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

condition.
20-106
(5)
1
D375A-5

MEASURING EXHAUST COLOR
MEASURING EXHAUST COLOR

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

Tools for adjusting
Symbol
Part No.
795-799-5510
Part Name
Heat gun
If the engine power down and bad combustion

seems to be caused by defective fuel injection,
perform troubleshooting for the injector according to the following procedure.
1. Stop the engine and wait for it to cool down.
A guideline for judging if the engine has
cooled down is that the temperature of the
exhaust manifold is less than 20C above the
ambient temperature.
2. Make measurement marks a to the exhaust
manifold outlets of the all cylinders.
Make the marks at the same points of the
tops or bottoms of the exhaust manifolds of
the all cylinders.
6. Compensate the measured value for each cylinder 12 minutes after starting the engine and
judge if there is any cylinder with a problem.
Compensation value
Unit: C
Cylinder
Compensation
value
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6

+20
+5
+5
+20
Method of judgement
After compensating, add up the values for
the exhaust gas temperature and calculate
the average value. Any cylinder that is more
than 20C lower than the average value can
be considered abnormal.
Measurement and judgement example 1
No. 2 cylinder is more than 20C lower than
the average value, so judge it as abnormal.
Unit: C
Cylinder
3. Using heat gun D, measure the temperature at

the exhaust manifold outlet port of each cylinder
before starting the engine.
Apply the measurement light (center) of the
heat gun to mark a of each cylinder to prevent dispersion of the measurement results
caused by difference of the measuring
points.
4. Run the engine at low idling speed.
5. Using heat gun D, measure the temperature at
the exhaust manifold outlet port of each cylinder
3 minutes, 6 minutes, 9 minutes, and 12 minutes
after starting the engine.
Apply the measurement light (center) of the
heat gun to mark a of each cylinder to prevent dispersion of the measurement results
caused by difference of the measuring
points.
85
62
79
112
89
82
Compensated
value
105
67
79
112
94
102
Average value
4
1
93

No. 3 cylinder is more than 20C lower than
the average value, so judge it as abnormal.
Unit: C
Cylinder
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Measured value
86
96
73
91
94
103
Compensated
value
106
101
73
91
99
123
Average value
99

No cylinder is more than 20C lower than the
average value, so judge all cylinders as normal.
Unit: C
Cylinder
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Measured value
70
88
88
93
86
72
Compensated
value
90
93
88
93
91
92
Average value
20-108
No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
Measured value
91
D375A-5
ADJUSTING VALVE CLEARANCE
ADJUSTING VALVE CLEARANCE

Tools for adjusting valve clearance
Symbol
Part No.
Commercially
available
Part Name
Thickness gauge
1. Open the engine left side cover and right side

cover.
2. Remove all cylinder head covers (1).
4. Insert thickness gauge E2 into clearance b between rocker arm (3) and crosshead (4), and adjust the valve clearance with adjustment screw
(5).
Insert the thickness gauge and turn the adjustment screw until the clearance is a sliding fit.
3. Rotate the crankshaft in the normal direction, to

set the No. 1 cylinder at compression top dead
center, and align [1.6TOP] line a on the damper
with pointer (2).
Crank the engine with barring device 1 of
the flywheel housing.
At compression top dead center, the rocker

arm of the No. 1 cylinder can be moved by
hand an amount equal to the valve clearance. If the rocker arm does not move, it is
not at compression top dead center, so rotate the crankshaft one more turn.
5. Hold adjustment screw (5) in position, then tighten locknut (6).

3 Locknut:
57.8 - 77.4 Nm {5.9 - 7.9 kgm}

After tightening the locknut, check the valve
clearance again.
6. Rotate the crankshaft 120 each time in the normal direction and repeat the procedure in Steps
3 - 5 to adjust the valve clearance of each cylinder according to the firing order.
Firing order: 1-5-3-6-2-4
7. After completing the adjustment, set to the original condition.
3 Cylinder head cover mounting bolt:
9.8 1.0Nm{1.0 0.1kgm}
D375A-5
20-109
(5)
1
ADJUSTING INJECTOR SET LOAD

1. Open the engine left side cover and right side
cover.
3. Rotate the crankshaft in the normal direction,

align [1.6TOP] line a on the damper with pointer
(2), and set the No. 1 cylinder at compression top
dead center.
Crank the engine with barring device 1 of
the flywheel housing.
Cylinder at compression top dead center and

cylinder where injector is adjusted
Compression top
dead center
Injector to be
adjusted
4. Loosen locknut (4) of the injector to be adjusted.

Completely loosen adjustment screw (3), then
tighten it with your fingers.
Check that the bearing at the tip of the rocker
arm and the ball at the push rod end are fitted securely in the injector and push rod respectively.
5. Tighten and loosen adjustment screw (3) repeatedly in the following order, then tighten it finally.
3 Adjustment screw:
At compression top dead center, the rocker

arm of the No. 1 cylinder can be moved by
hand and amount equal to the valve clearance. If the rocker arm does not move, it is
not at compression top dead center, so rotate the crankshaft one more turn.
The cylinder where the injector is adjusted is
different from the cylinder at compression
top dead center, so check the chart below
when carrying out the operation.
20-110
(5)
1
1st pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}

2nd pass: Loosen completely
3rd pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
4th pass: Loosen completely
5th pass: 29.4 - 34.3 Nm {3.0 - 3.5 kgm}
D375A-5
6. Hold adjustment screw (3) in position, then tighten locknut (4).
3 Locknut: 205.8 - 245 Nm {21 - 25 kgm}
7. After completing the adjusting, set to the original

condition.
9.8 1.0Nm{1.0 0.1kgm}
D375A-5
20-111
(5)
1

MEASURING COMPRESSION PRESSURE

a Measuring instruments for compression pressure
Symbol
1
Part No.
3. Remove rocker arm assemblies (1) of all the cylinders.
Part Name
795-502-1590
Compression gauge
795-611-1210
Adapter
6560-11-8410
O-ring (TOP)
6560-11-8310
O-ring (2ND)
6560-11-8210
O-ring (3RD)
6560-11-8510
O-ring (4TH)
6560-11-7310
Gasket
795-799-5410
Adapter
795-799-5420
Remover
When measuring the compression pressure,

take care not to burn yourself on the exhaust
manifold, muffler, etc. or get caught in a rotating
part.
a Measure the compression pressure after the engine is warmed up.
(Engine oil temperature: 40 60C)
a Since the compression pressure of all the cylinders should be measured at the same time for efficiency, preapre 6 adapter assemblies F2.
4. Remove injector push rods (2) and injectors (3)

of all the cylinders.
a Using remover F3, pull out each injector.
1. Open the right side cover and left side cover of

the engine.
5. Install adapter assemblies F2 to the all cylinders

and secure them with the holders.
a Install the adapter assemblies with the forcing screw holes directed in the diagonal direction of the holders.
a Secure the adapter assemblies with the injector holders.
3 Holder mounting bolt:
24.5 34.3 Nm {2.5 3.5 kgm}
20-111-1
(5)
D375A-5
6. Install rocker arm assemblies (1) and adjust the

valve clearance.
2 Threads and seat of mounting bolt:

3 Mounting bolt:
8. Connect compression gauge F1 to adapter assembly F2 of the cylinder to be measured.
Engine oil (EO30CD)
235.2 254.8 Nm {24 26 kgm}

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

measure the compression pressure.
a Read the gauge when its pointer is stabilized.
7. Disconnect the EG1 (POW) connector and EG2

(SIG) connector (4) of the engine.
a After this step, the fuel pump does not supply
fuel to the injectors.
10. After finishing measurement, remove the measuring instruments and return the removed
parts.
a Measure the stem length of the injector holder mounting bolt. If it is longer than 80 mm,
replace the bolt.
2 Threads and seat of
holder mounting bolt:

Engine oil (EO30CD)
1st time:
24.5 34.3 Nm {2.5 3.5 kgm}
2nd time:
Tighten by 90 120
2 Threads and seat of rocker arm
assembly mounting bolt:

Engine oil (EO30CD)
3 Rocker arm assembly mounting bolt:
235.2 254.8 Nm {24 26 kgm}

a Adjust the valve clearance. For details, see
ADJUSTING VALVE CLEARANCE.
a Adjust the set load of the injector. For details,
see ADJUSTING SET LOAD OF INJECTOR.
9.8 1.0 Nm {1 0.1 kgm}
D375A-5
20-111-2
(5)
MEASURING BLOW-BY PRESSURE
MEASURING BLOW-BY PRESSURE

Tools for measuring blow-by pressure
Symbol
Part No.
799-201-1504
Part Name
Blow-by kit
Measure the blow-by pressure under the following conditions.

Blow-by varies greatly according to the condition of the engine. Therefore, if the blow-by
value is considered abnormal, check for
problems connected with defective blow-by,
such as excessive oil consumption, defective
exhaust gas color, and prematurely dirty or
deteriorated oil.
1. Open the engine left side cover and pull out

blow-by hose (1).
2. Install nozzle 1 of blow-by checker G to blow-by
hose (1), then connect to gauge 2.

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

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

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

each engine speed.
a Check that the fuel pump outlet pressure
is in the following range.
a Fuel pump outlet pressure:
Engine
speed
3) Start the engine, set the monitor panel in the

MONITORING MODE, and prepare for measuring the engine speed.
a For the operating method, see SPECIAL
FUNCTIONS OF MONITOR PANEL
(EMMS).
a The engine speed is displayed on the
service meter display section in 1 rpm.
Fuel pump outlet

pressure
Sensor
voltage
(Reference)
600 rpm
0.83 0.14 MPa

1.78 0.21 V
{8.45 1.41 kg/cm2}
700 rpm
0.93 0.14 MPa

1.94 0.21 V
{9.50 1.41 kg/cm2}
800 rpm
1.03 0.14 MPa

2.10 0.21 V
{10.53 1.41 kg/cm2}
900 rpm
1.14 0.14 MPa

2.26 0.21 V
{11.60 1.41 kg/cm2}
1,000 rpm
1.25 0.14 MPa

2.42 0.21 V
{12.70 1.41 kg/cm2}
1,100 rpm
1.34 0.14 MPa

2.59 0.21 V
{13.70 1.41 kg/cm2}
1,200 rpm
1.46 0.14 MPa

2.76 0.21 V
{14.90 1.41 kg/cm2}
a The sensor voltage shown in the above

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

measuring instruments and return the removed parts.
20-114-2
(5)
D375A-5
VISUAL INSPECTION OF RETURN FUEL
VISUAL INSPECTION OF RETURN FUEL

The fuel used for control of the timing rail in the
fuel circuit and the excessive fuel that is not used
injected in the fuel rail are returned from the injector through the fuel cooler to the fuel tank.
If the engine does not revolve normally or fuel
consumption is abnormally high, inspect the spill
fuel according to the following procedure.
1. Disconnect fuel return hose before the fuel tank.
Plug the hole of the fuel tank.
Keep the spill hose open and receive the fuel
with an oil pan, etc.
2. Start the engine and check that the fuel flows out
of the spill hose smoothly.
Spillage (Referene)
At low idling: 4 6 /min.
At high idling: 10 12 /min.
If the spillage is extremely low, check the return piping and fuel cooler for clogging.
D375A-5
20-115
4
1

ARRANGEMENT OF CONTROL DEVICES FOR HPI

Arrangement of control devices (for troubleshooting)
20-115-1
(5)
D375A-5
Controller pump valve

1. Engine controller
2. Fuel pump assembly
Sensors
4. Atmospheric pressure sensor (AAPR)
5. Boost pressure sensor (IMPR)
6. Intake air temperature sensor (IMTP)
7. Oil pressure sensor (OPS)
8. Fuel temperature sensor (FLTP)
9. Water temperature sensor (CLTP)
10. Speed sensor (SP1, SP2)
11. Fuel pump pressure sensor (PMPR)
12. Fuel rail pressure sensor (RPR)
13. Timing rail pressure sensor (TRP)
Actuator
14. Fuel pump actuator (PUMP)
15. Fuel shut-off valve (FSO+, FSO)
16. Fuel rail actuator (RAIL)
17. Timing rail actuator (TIMG)
D375A-5
20-115-2
(5)
BLEEDING AIR FROM FUEL CIRCUIT
If the engine does not start or is difficult to start

after the following operations or conditions,
bleed the air from the fuel circuit as follows.
When starting the engine for the first time
After cleaning the fuel tank
After adding fuel when the engine has stalled
After replacing the fuel filter (only when the
air is not bled easily)
Add fuel from the inlet port a (8 places). Portion b is the outlet port after filtering (clean
side), so never add fuel from portion b.
1. Open the stop valve at the fuel tank supply side,

then open the engine right side cover.
Check that there is ample fuel in the fuel
tank.
2. Remove fuel filter (1), fill it with fuel, then install it
again.
Carry out this operation only if the fuel filter
has been replaced.
If the fuel filter is not to be replaced, there is
danger of dirt getting in, so do not remove
the fuel filter.
20-116
1
D375A-5
3. Crank the engine with the starting motor, push

air bleed the valve (1), and bleed the air from the
vent circuit.
There is no problem with starting even if
some air is in the circuit, so if the fuel flows
out the bleeding operation is completed.
4. Start the engine and run at low idling.
The injector is an open circuit, so while the
engine is running the air remaining in the circuit is released from the injector to the inside
of the engine or the fuel tank.
After the engine is started, the engine rotation will be slightly unstable until the air remaining in the circuit is completely bled, so
continue to run the engine at low idling until
it stabilizes.
If the engine will still not start after the above operation, fill the fuel pump with fuel as follows.
1) Remove air bleed valve (1).
2) Fill with clean fuel through the hole in the
valve until it overflows.
Amount of fuel to add: Approx. 30 cc (reference)
3) Install air bleed plug (1).
Air bleed plug: 12.7 Nm {1.3 kgm}
4) Crank the engine with the starting motor.
D375A-5
20-117
ADJUSTING ENGINE SPEED SENSOR
ADJUSTING ENGINE SPEED SENSOR

If the engine speed sensor has been removed
and installed or the flywheel has been removed
or installed, adjust as follows.
1. Remove the floor inspection cover, then remove
engine speed sensor (1).
Before adjusting, remove the engine speed
sensor, check that the tip of the sensor is not
scratched and that there are no iron particles
sticking to it, then install it again.
5. After completing the adjustment, switch the

monitor panel to the monitoring mode display,
and check that the engine speed is displayed
normally.
For details of the method of operation, see
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS).
2. Screw in engine speed sensor (1) until its tip
lightly touches the tooth tip of flywheel ring gear
(2).
Before installing the sensor, check that its tip
is free from steel chips and flaws.
2 Threads:
Hydraulic sealant (No. 21028)
manufactured by LOCTITE
3. Return engine speed sensor (1) by 1/2 3/4

turns.
Adjust clearance a between the engine
speed sensor tip and gear tooth tip to 0.75
1.25 mm.
4. Hold engine speed sensor (1) and tighten locknut (3).
3 Locknut:
33.9 - 47.5 Nm {3.5 - 4.8 kgm}
20-118
4
1
D375A-5
REPLACING AND ADJUSTING FAN BELT
REPLACING AND ADJUSTING FAN BELT

Replacing
1. Open the engine right side cover.
2. Loosen locknut (1), then turn adjustment screw
(2) back fully.
3. Use one of the following methods to loosen the
belt tension.
1) Insert bar (approx. 50 cm) into hole a (M12
x 1.75) in tension pulley lever (3), pull strongly and keep the tension of the fan belt loosened.
2) Remove adjustment screw (2), then screw it
into hole b (M16 x 1.0) of bracket (4) and
loosen the tension.
After replacing the belts, set the adjustment screw back to its original condition.
Adjusting
If the fan belt whines during operation, or a gap
forms between the tension pulley lever and the
adjustment screw, adjust as follows.
1. Screw in adjustment screw (2) until the tip contacts tension pulley lever (3).
2. From this position, tighten adjustment screw (2) a

further 2 turns, then secure in position with locknut (1).
Locknut:
245.0 - 308.7 Nm {25.0 - 31.5 kgm}
4. Remove the old fan belts and replace them with

new belts.
D375A-5
20-119
TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER

COMPRESSOR BELT TENSION
TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER

COMPRESSOR BELT TENSION
Testing
Measure deflection a when a point midway between the alternator pulley and the air conditioner compressor pulley (or idler pulley) is pressed
with a finger.
Pushing force: Approx. 98 N {approx. 10 kg}
Adjusting
If the deflection is not correct, adjust as follows.
1. Loosen the 2 alternator mounting bolts and 1
lock bolt for the adjustment rod.
2. Loosen locknut (1), then turn adjustment nut (2)
to move alternator (3) and adjust the belt tension.

3. Tighten the 2 alternator mounting bolts and 1

lock bolt for the adjustment rod.
20-120
Alternator mounting bolt (4):

65 - 85 Nm {6.7 - 8.7 kgm}
Alternator locknut (1):
147 - 247 Nm {15 - 25 kgm}
D375A-5
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
1. Outline of fuel control system

The speed signals from the fuel control dial
and decelerator pedal (decelerator potentiometer) are both input to the engine controller (the signal from the fuel control dial
passes through the steering controller).
The controller gives priority to the lower of
these two speed signals and sends a command to the fuel control system (HPI system)
of the engine.
Adjustment of the engine speed is all carried
out by the linkage of the deceleration pedal.
D375A-5
20-121
1
2. Preparatory work
1) Start the engine, switch the monitor panel to
the monitoring mode display, and prepare to
measure the engine speed.
For details of the method of operation,
see SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS).
The engine speed is displayed on the
service meter display section in 1 rpm.
3. Adjusting deceleration pedal speed

With the fuel control dial in the high idling position, press decelerator pedal (2) until it touches
the stopper. Check that the decelerator pedal
speed is normal under this condition.
Deceleration speed: 900 50 rpm
If the deceleration speed is not correct, adjust installed dimension a of rod (1).
Standard installed dimension a of rod: 124
mm (reference)
4. High idling speed
Set the fuel control dial to the high idling position
and check that the high idling speed is correct.
High idling speed: 1900 25 rpm
If the high idling speed is abnormal, adjust it
according to the following procedure.
If the engine speed is more than 1850 rpm:
To remove the play of the decelerator pedal,
use stopper bolt (3) to adjust the engine
speed to less than 1800 rpm, then adjust to
the high idling speed.
If the engine speed is less than 1850 rpm:
Use stopper bolt (3) to adjust to the high
idling speed.
2) Set the fuel control dial to the high idling position and check that the engine speed is at
least 1000 rpm.
If the engine speed is less than 1000
rpm, extend installation dimension a of
rod (1) to raise the speed to above 1000
rpm.
20-122
(5)
1
D375A-5
1. Measuring torque converter inlet pressure

(IN)
1) Connect oil pressure gauge (1) of hydraulic
tester H1 to oil pressure measurement nipple (1).
Use a 2.5 MPa {25 kg/cm2} oil pressure
gauge.
2) Start the engine and set all the functions of

the PCCS lever to neutral.
3) Measure the oil pressure with the engine at
low idling and high idling.

20-124
1
MEASURING POWER TRAIN OIL PRESSURE
2. Measuring torque converter outlet pressure

(OUT)
1) Connect hydraulic tester H2 to oil pressure
measurement nipple (2).
gauge.


D375A-5
3. Measuring torque converter lock-up clutch

pressure (LU)
1) Connect oil pressure gauge 1 of hydraulic
gauge.
3) Set the parking brake lever in the FREE position and turn the lock-up mode switch ON.
4) Set the PCCS lever direction to F and the
speed to the 1st, and rotate the transmission
under no load.
5) Gradually raise the engine speed, and measure the oil pressure when the lock-up pilot
lamp lights up.
2) Start the engine and set the monitor panel in

the "Adjustment mode" and disengage both
steering clutches.
For the operating method, see "Special
functions of monitor panel (EMMS)".
Adjustment code: Co (Disengagement of
both steering clutches)
The transmission speed is displayed on
the service meter display section (Unit: 1
rpm).
D375A-5

20-125
(5)
1
4. Measuring torque converter stator clutch

pressure (SC)
gauge.
5. Measuring transmission main relief pressure

(TM)
gauge.




20-126
1
D375A-5
6. Measuring transmission F clutch pressure

(FWD)
1) Connect oil pressure gauge
of hydraulic
gauge.
7. Measuring transmission R clutch pressure

(R)
of hydraulic
gauge.

steering clutches.
For the display on the panel, see "5.
Measuring torque converter lock-up
clutch pressure (LU)".
3) Set the parking brake lever in the FREE position.
4) Keep pressing the brake pedal, set the
PCCS lever direction to F and the speed to
the 3rd, and rotate the transmission under no
load.
5) Measure the oil pressure at low idling.

steering clutches.
PCCS lever direction to R and the speed to
load.


D375A-5
20-127
8. Measuring transmission 1st clutch pressure

(1ST)
of hydraulic
gauge.
9. Measuring transmission 2nd clutch pressure

(2ND)
of hydraulic
gauge.

steering clutches.
the 1st, and rotate the transmission under no
load.

steering clutches.
the 2nd, and rotate the transmission under
no load.


20-128
D375A-5
10. Measuring transmission 3rd clutch pressure

(3RD)
of hydraulic
gauge.

steering clutches.
load.
11. Measuring left steering clutch pressure (LC)

of hydraulic
gauge.
2) Start the engine and set the parking lever to

the FREE position.
3) Operate the PCCS lever steering fully to the
left.
Set the direction to the neutral position.
Check that the oil pressure becomes 0
when the PCCS lever steering is returned to neutral.


D375A-5
20-129
12. Measuring left steering brake pressure (LB)

of hydraulic
tester H1 to oil pressure measurement nipple
(12).
gauge.
13. Measuring right steering clutch pressure (RC)

of hydraulic
tester H1 to oil pressure measurement nipple
(13).
gauge.

the FREE position.
when the PCCS lever steering is operated fully to the left.
when the brake pedal is depressed or the
parking lever is operated to the LOCK position.

the FREE position.
right.
Set the direction to the neutral position.
when the PCCS lever steering is returned
to neutral.

20-130

D375A-5
14. Measuring right steering brake pressure (RB)

gauge.

the FREE position.
when the PCCS lever steering is operated fully to the right.
when the brake pedal is depressed or
the parking lever is operated to the
LOCK position.
15. Measuring transmission lubrication pressure

1) Connect hydraulic tester H2 to oil pressure
measurement nipple (15).
gauge.
2) Start the engine and measure the oil pressure with the engine at high idling.


D375A-5
20-131
1


16. Measuring output pressure of sudden stop
prevention valve
tester H1 to oil pressure pickup nipples (12)
and (14).
a Use the oil pressure gauge of 5.9 MPa
{60 kg/cm2}.
(12): For steering left brake
(14): For steering right brake

ADJUSTMENT MODE, and set the sudden
stop prevention valve in the operation mode.
(EMMS).
a Adjustment code:
b5 (Operation mode of sudden stop
prevention valve)
a The voltage of the brake pedal potentiometer is displayed on the service meter
display section (in 1 mV).
3) Set the parking brake lever in the FREE position and set the PCCS lever in the ALL
NEUTRAL position.
4) Run the engine at low idling and measure
the oil pressure.
a If the output pressure of the sudden stop
prevention valve is as follows, it is normal.
1.13 1.57 MPa {11.5 16.0 kg/cm2}

20-131-1
(5)
D375A-5
ADJUSTING TRANSMISSION SPEED SENSOR

SIMPLE PROCEDURE
FOR TESTING
BRAKE SPEED
PERFORMANCE
ADJUSTING
TRANSMISSION
SENSOR
ADJUSTING TRANSMISSION
SPEED SENSOR
1. Remove the cover at the bottom of the fuel tank,
then remove transmission speed sensor (1).
Before adjusting, remove the transmission
speed sensor, and check that the tip of the
sensor is not scratched and that there are no
iron particles sticking to it.
SIMPLE PROCEDURE FOR

TESTING BRAKE PERFORMANCE
Carry out the simple test of the brake performance under the following conditions.
1. Stop the machine on a level surface and set the
blade and ripper to the travel posture.
2. Screw in transmission speed sensor (1) until its

tip lightly touches the tooth tip of gear (2).
2 Threads of sensor:
Gasket sealant (LG-5)
3. Return transmission speed sensor (1) by 1/2 1

turn.
Adjust clearance a between the engine
speed sensor tip and gear tooth tip to 0.75
1.25 mm.
4. Hold transmission speed sensor (1) and tighten
locknut (3).
3 Nut: 49.0 - 68.6 Nm {5 - 7 kgm}
2. Start the engine and set the parking lever to the

FREE position.
3. With the engine at low idling, depress the brake
pedal firmly, and set the PCCS lever direction to
F and the speed to 2.
If it is set to 1, there will be excess load on
the brakes, so always carry out this test in
position 2.
Set the steering to the neutral position.
4. Depress the decelerator pedal and set the fuel
control lever to the high idling position.
5. Release the decelerator pedal gradually and
raise the engine speed to high idling. Check that
the machine does not start to move.
The torque converter is stalled, so keep the
brake pedal depressed firmly during the operation. For safety reasons, always keep
your right foot on the decelerator pedal until
the completion of the measurement operation.
5. After completing the adjustment, switch the monitor panel to the monitoring mode display, and
check that the transmission speed is displayed
normally.
For details of the method of operation, see
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS).
Monitoring code: 70 (Transmission speed)
20-132
4
1
D375A-5
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER

Adjusting brake pedal
Adjusting parking lever
D375A-5
20-133
(5)
1
Adjusting brake pedal

1. Adjusting travel of brake pedal
Adjust installation dimension b of stopper bolt (2)
so that the travel of brake pedal (1) is dimension
a.
When adjusting the travel of the brake pedal,
disconnect the brake rod from the pedal.
Pedal travel a: 74 mm
Stopper bolt installation dimension b: 42 mm
2. Adjusting installed length of brake rod
1) Install brake rod (3) and release brake pedal
(1) (do not depress it).
2) Adjust installed dimensions c and d of brake
rod (3) with turnbuckle (5) so that the spool
of brake valve (4) is at the OFF position.
The locknut of the turnbuckle has a lefthanded thread (reverse thread) at the
brake pedal end.
Installed dimension c: 32 mm
Installed dimension d: 14 mm
3 Locknut:
34.3 58.8 Nm {3.5 6.0 kgm}
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.
Spool travel e: 19 23 mm
5. Initial setting of brake potentiometer

Turn the starting switch ON, set the monitor panel in the ADJUSTMENT MODE, and set the
brake potentiometer to the initial value.
For the operating method, see SPECIAL
F U N C T I O N S O F M O N I TO R PA N E L
(EMMS).
Adjustment code:
bP (Setting brake pedal standard position)
Adjusting parking lever
6. Assembly and installation of lever assembly
1) Assemble lever assembly (7) and adjust the
actuation of limit switch (8).
When assembling the lever assembly,
disconnect the parking cable from the lever.
Lever raised: OFF, lever lowered: ON
Limit switch actuation travel: 3 mm
2) Install lever assembly (7).
7. Adjusting installed length of parking cable
1) Connect parking cable (9) to the lever and
valve, then adjust installed dimensions f and
g.
Installed dimension f of cable: 112.8 mm
Installed dimension g of cable: 114.0 mm
2) Operate parking lever (10) between the
FREE position and LOCK position, and adjust the position of rod end (11) so that spool
travel h of brake valve (4) is correct.
Spool travel h: 23.0 mm
4. Checking brake oil pressure

the ADJUSTMENT MODE.
For the operating method, see SPECIAL
(EMMS).
Adjustment code:
bL (Brake release mode)
2) With the parking brake lever in the FREE position, press the brake pedal and check that
the brake oil pressures on both sides become 0.
For the measuring points of the brake oil
pressure, see MEASURING POWER
TRAIN OIL PRESSURE.
20-134
(5)
1
D375A-5


8. Checking brake oil pressure
Start the engine, set the parking brake lever in
the FREE position and LOCK position, and
check that the brake oil pressure becomes as follows at the respective positions.
a For details of the method of measuring the
brake oil pressure, see MEASURING POWER TRAIN OIL PRESSURE.
LOCK position: 0, FREE position: Specified
pressure
9. Checking limit switch
1) Turn the starting switch ON and set the monitor panel in the MONITORING MODE.
(EMMS).
Monitoring code:
L9 (Steering controller switch input 1)
2) Set the parking brake lever in the FREE position and LOCK position and check that the
limit switch signals are input normally at the
respective positions.
D375A-5
20-134-1
(5)
ADJUSTING POSITION OF PCCS LEVER CONSOLE
ADJUSTING POSITION OF PCCS LEVER CONSOLE
1. Set operators seat (1) facing the front (dozing

position).
2. In this condition, check that console (2) is parallel
to operators seat (1).
If it is not parallel, adjust installed dimension
a of rod (3).
Standard installed dimension a: 179 mm
The locknut at the rear of the turnbuckle has
a left-handed thread (reverse thread)
D375A-5
20-135
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER

TRAIN
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN

POWER TRAIN
Insert switch assembly

inside the cab
through the cab window.
Tools for emergency escape

Symbol
Part No.
Part Name
19M-06-32820
Switch assembly
7824-66-6430
Resistor
195-06-71220
Wiring harness
790-190-1600
Pump assembly
1. Emergency escape method using switch box

(using K1)
If a problem occurs in the electrical system of
the power train control (direction, speed,
steering) and the machine does not move,
carry out the emergency escape as follows.
With this procedure, it is necessary to be
able to start the engine. If the engine will not
start, see EMERGENCY ESCAPE METHOD USING BRAKE RELEASE DEVICE.
1) Connect switch assembly
and resistor
to wiring harness
of emergency escape
device K1.
Resistor
controls the drive voltage of
the solenoid, so connect it before connecting the wiring harness to the machine.
In order to prevent mistaken actuation,
set all the speed range switches of
switch assembly
to the OFF position
and the directional switch to the P position.
2) Open the inspection cover on the left fender

and connect wiring harness
to PL1 connector (1) and PL2 connector (2).
PL1 connector (1): Connect to male and
female ends
PL2 connector (2): Connect to male end
The female end of connector PL2 remains disconnected, so cover it with vinyl.
3) Disconnect the neutral safety relay (NSF) inside the fuse room, then connect pin
and
pin
of the connector at the wiring harness
end directly.
With this operation, the neutral safety relay or transmission controller will not
work, so carry out this operation only if
the engine will not start electrically.
With this method, if the engine starts, the
neutral safety relay function will not
work, so before starting the engine, set
the parking lever to the LOCK position
and all the PCCS lever functions to the
neutral position.
With this method, start the engine only
when carrying out the emergency escape. In all other cases when the engine
does not start, always carry out troubleshooting and repair the cause.
20-136

the FREE position.
5) Operate switch assembly
and move the
machine to a safe place.
The speed switch has an electric circuit
that gives priority to operation of the low
speed switch.
D375A-5
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER

TRAIN
2. Emergency escape method using brake release device (using K2)

If the engine cannot be started, and the parking brake cannot be released, carry out the
emergency escape as follows.
1) Assemble pump assembly K2.
2) Set volume pump 1 of pump assembly K2

on the outside of the operators cab.
4) Connect the hose at the tip of pump assembly K2 to the supply hose.
Block the solenoid valve end with a plug.
5) Turn the starting switch ON and set the parking lever to the FREE position.
6) Operate the volume pump to raise the brake
release oil pressure to the initial pressure.
Initial pressure: approx. 2.74 MPa {approx. 28 kg/cm2}
An accumulator is installed in the circuit,
so it is necessary to operate the handle
30 - 50 times to raise the oil pressure.
If the pressure does not go above the set
pressure, the set pressure of the relief
valve may be too low, so adjust it.
7) Tow the machine to a safe place.
The brake release oil pressure will go
down gradually because of internal leakage, and the brake will be actuated after
approx. one minute, so carry out the operation quickly.
When the brake release pressure goes
down to approx. 1.57 MPa {16 kg/cm2},
the brake is actuated. If this happens,
operate the volume pump again to raise
the brake release pressure to the initial
pressure.
3) Remove the cover at the bottom of the fuel

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

CHECKING WEAR OF SPROCKET
ADJUSTING IDLER
CLEARANCE
CHECKING WEAR OF
SPROCKET
If there is wear of the idler side guide, top and

bottom guide, or guide plate, and the idler sways
to the side or is at an angle, adjust as follows.
Copy the SPROCKET TOOTH BASIC DIMENSION DRAWING on a clear paper or sheet, and
place it directly on the sprocket to judge pass/fail
for the sprocket wear.
1. Travel for 1 - 2 m on flat ground, then measure

clearance a (outside, inside).
2. If clearance a is more than 3 mm, remove bolt (1)
and reduce shim (2) to adjust.
Standard clearance a on one side: 0 - 0.5
mm
Types of shim thickness: 0.5 mm, 1.0 mm
When the machine is new, 10 mm thickness
of shim is installed on each side.
When adjusting, reduce the shim thickness
uniformly on the inside and outside.
20-138
Mounting bolt:
824 - 1030 Nm {84 - 105 kgm}
D375A-5
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING TRACK SHOE TENSION

Testing
1. Drive the machine forward and stop on a horizontal surface.
Stop the machine without using the brake.
3. If tension is too low:

Pump in grease through grease fitting (4).
If the the track tension is poor, move the machine backwards or forwards slowly.
2. Put straight steel rod (1) on top of the track between the idler and front carrier roller, and measure clearance a from the bottom of the steel rod
to the track shoe grouser.
Standard clearance a: 20 - 30 mm
Adjusting
If the track shoe tension is not correct, adjust as
follows.
2. If tension is too high:

Loosen plug (3) and release some of the grease.
There is danger that the plug may fly out under the high internal pressure of the grease,
so never loosen the plug more than 1 turn.
3 Plug: 59 - 88 Nm {6 - 9 kgm}
D375A-5
20-139
1
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
2. Measuring center pump relief pressure

1) Remove work equipment small pump pressure sensor (10).
2) Install adapter Q2, nipple 1 of hydraulic

tester Q1, and pressure sensor (10), and
connect them to oil pressure gauge 2.
Use the oil pressure gauge of 39.2 MPa
{400 kg/cm2}.
4) Run the engine at low idling and high idling

and operate the blade lever or ripper lever to
relieve each cylinder circuit. Measure the oil
pressure at this time.

3) Start the engine and reset the safety lock lever.
D375A-5
20-141
(5)
1


Measuring (Measuring with monitor panel)
a Meaure the work equipment oil pressure under
the following condition.
1. Measuring front pump relief pressure
1) Disconnect the blade lift cylinder hoses from
the cylinder and block the control valve side.
Flange for blocking:
07379-01260 (4 pieces)
a Stop the cylinder side, too, with cork
stoppers, etc.
MONITORING MODE, and prepare for measuring the oil pressure.
(EMMS).
Monitoring code:
HL (Work equipment large pump oil
pressure)
a The oil pressure is displayed on the service meter display section in 1 kg/cm2.
20-141-1
(5)

and operate the blade lever to relieve the
blade lift cylinder circuit. Measure the oil
D375A-5
2. Measuring center pump relief oil pressure

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

2) Remove cover (2).
3) Loosen locknut (3), then turn adjustment
screw (4) to adjust.
a Turn the adjustment screw as follows.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTERCLOCKWISE
a Amount of adjustment for one turn of adjustment screw:
Approx. 2.43 MPa (approx. 24.8 kg/cm2)
3 Locknut :
11.8 14.7 Nm {1.2 1.5 kgm}
3 Cover:
4) Install cover (2).
29.4 39.2 Nm {3 4 kgm}

and operate the blade lever or ripper lever to
relieve each cylinder circuit. Measure the oil
5) After completion of the adjustment, repeat

the above procedure to check the oil pressure again.
D375A-5
20-141-2
(5)
2. Adjusting center pump relief pressure

If the center pump relief pressure are not
correct, adjust main relief valve (5) of the
blade tilt and ripper Lo valve as follows.

1) Remove the right side cover.

Turn the adjustment screw as follows.
To INCREASE pressure, turn CLOCKWISE
To DECREASE pressure, turn COUNTERCLOCKWISE
Amount of adjustment for one turn of adjustment screw: Approx. 2.43 MPa (approx. 24.8 kg/cm2)
3 Cover: 29.4 - 39.2 Nm {3 - 4 kgm}
20-142
(5)
1
D375A-5
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
Adjusting
If the control circuit main pressure is not correct,
adjust charge relief valve (2) as follows.

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

20-144
(5)
1
D375A-5
20-146
1
MEASURING PPC VALVE OUTPUT PRESSURE
D375A-5
ADJUSTING PLAY OF PPC VALVE
ADJUSTING PLAY OF PPC VALVE

If there is excessive play at the tip of the ripper
lever and blade lever, adjust the PPC valve as
follows.
The diagram shows the PPC valve for the ripper.
Standard play dimension a:
0.5 - 3.0 mm at a point 200 mm from rotation
center of lever (both to front and rear, and to
left and right)
1. Remove boot (1).
2. Loosen locknut (2) and rotate disc (3) to adjust
the amount of play.
When doing this, do not make the piston
move.
3. Secure disc (3) in position and tighten locknut
(2).
3 Locknut: 98 - 127 Nm {10 - 13 kgm}
4. Install boot (1).
D375A-5
20-147
1
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND

RIPPER
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF

BLADE AND RIPPER
If hydraulic drift occurs in the blade or ripper,
check as follows to see if the cause is in the cylinder packing or in the control valve.
1. Set the cylinder to be inspected to the following
posture, then stop the engine.
1) Blade lift cylinder
Push the blade against the ground to raise
the front of the chassis.
The blade lift cylinder has a built-in piston valve, so do not operate the cylinder
to the end of the stroke.
2. Operate the control lever in the direction to extend the cylinder rod, and check the movement
of the cylinder.
If the downward movement becomes faster,
the packing is defective.
If there is no change, the control valve is defective.
If there is no more pressure in the accumulator, run the engine for approx. 10 seconds to
charge the accumulator.
2) Blade tilt cylinder
Extend the tilt cylinder rod fully, then push
the blade against the ground to raise the
right side of the chassis.
3) Ripper lift cylinder

Push the ripper against the ground to raise
the rear of the chassis.
D375A-5
[Reference:] If the cause of the hydraulic drift is in

the packing, the speed of downward
movement in the above operation will
become faster for the following reasons.
1) When the work equipment is set to the posture
given above, (holding pressure applied to the
bottom end), oil will leak from the bottom end to
the head end. However, the volume at the head
end is smaller than at the bottom end (by an
amount proportional to the volume of the rod), so
if the oil flows in from the bottom end, the internal
pressure at the head end will rise.
2) If the internal pressure at the head end rises, a
balance will be made in proportion to this at a
certain pressure (this differs according to the
amount of leakage). When the pressure becomes balanced, the speed of downward movement becomes slower.
3) In this condition, if the lever is operated as shown
above, the circuit at the head end is connected to
the drain circuit (the bottom end is closed by a
check valve), and the oil at the head end flows to
the drain circuit. As a result, the balance is lost
and the speed of downward movement increases.)
20-149
1
MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER
MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER

Tools for measuring leakage from work equipment cylinder
Symbol
Part No.
Commercially
available
Part Name
Measuring cylinder
Measure the oil leakage inside the hydraulic cylinder under the following conditions.
The blade lift cylinder has a built-in piston valve,
so the internal leakage cannot be measured.
3. Run the engine at high idling and apply the relief

pressure to the bottom end of the cylinder.
Blade tilt cylinder: Extract the cylinder to be
measured
Ripper lift cylinder: Lower ripper
Ripper tilt cylinder: Tilt ripper to front
4. Wait for 30 seconds, then measure the amount
of leakage over the next 1 minute.
5. After completing the measurement, set to the
original condition.
1. Fully extend the cylinder to be measured, and

set to the measurement posture.
1) Blade tilt cylinder:
Extract the cylinder to be measured to the
stroke end.
2) Ripper lift cylinder:
Remove the shank pin and lower the ripper
fully.
3) Ripper tilt cylinder:
Tilt the ripper fully to the front.
2. Disconnect the piping at the head end of the cylinder and block the hose with an oil stopper plug.
Remove the cover when disconnecting the
blade tilt cylinder hose.
Be careful not to disconnect the hose at the
bottom end.
20-150
(5)
1
D375A-5
RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS

BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS
RELEASING REMAINING
PRESSURE IN WORK
EQUIPMENT CYLINDERS
When disconnecting the piping between the control valve and work equipment cylinder, first release the remaining pressure inside the circuit as
follows.
1. Loosen the oil filler cap slowly to release the
pressure inside the hydraulic tank.
2. Set the safety lock lever to the FREE position,
then operate the work equipment control levers
to the front, rear, left, and right.
When the levers are operated 2 - 3 times, the
pressure inside the accumulator is fully released.
3. Start the engine, run at low idling for approx. 5
seconds, then stop the engine.
BLEEDING AIR FROM WORK

EQUIPMENT CYLINDERS
After removing or installing work equipment cylinders or disconnecting and connecting hydraulic piping, bleed the air from the circuit as follows.
1. Start the engine and run at idling for about 5 minutes.
2. Run the engine at low idling, and extend and retract the cylinders 4 - 5 times.
Stop the piston rod about 100 mm before the
end of the stroke. Never operate it to the relief position.
3. Run the engine at high idling and repeat the procedure in Step 2.
4. Run the engine at low idling and operate the cylinder to the end of the stroke to relieve the circuit.
4. Repeat the operation in Steps 2 and 3 above 2 3 times.
D375A-5
20-151
1
ADJUSTING RIPPER LEVER POSITION
ADJUSTING RIPPER LEVER POSITION
Use the following procedure to adjust the ripper

lever to the optimum position.
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.
5) Loosen nut (3).

6) Turn knob (4) 180.
7) Tighten nut (3) to hold knob (4) in position.
1. Adjusting within range of 40 mm from center to

rear
1) Loosen lock bolt (1).
2) Set lever (2) to the optimum position.
3) Tighten lock bolt (1) to hold lever (2) in position.
2. Adjusting within range of 40 mm from center to
front
1) Loosen lock bolt (1).
2) Remove lever (2) and turn it 180.
3) Install lever (2) to lever (5), then set it to the
optimum position.
4) Tighten lock bolt (1) to hold lever (2) in position.
20-152
D375A-5
ADJUSTING BLADE
ADJUSTING BLADE
If the blade has been removed or disassembled,

adjust as follows.
1. Procedure for adjusting with shims when assembling
1) Use shims to adjust the clearance at center
portion (1).
Adjustment loca- Clearance
tion
1
2) Use shims to adjust the clearance at lift portion (2).

tion
2
Standard
clearance
Standard
shim thickness
Max. 1 mm
4.0mm
Standard
Standard
shim thickclearance
ness
See Note
4.5mm
Note: Adjust so that the play of the ball at the

spherical portion in the axial direction
is within 1 mm. Check that the ball rotates smoothly.
20-154
D375A-5
ADJUSTING BLADE
3) Use shims to adjust the clearance at trunnion

portion (3) (shim adjustment type).
tion
3
Standard
clearance
Standard
shim
thickness
1.560.65mm
Total clearance
12mm
2. Adjusting blade tilt

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

When adjusting the lever assembly
independently
1. Position lever in NEUTRAL (both forward & reverse, steering)

5 V pin and signal pin. (See table 1).
(ex. For ST1, measure resistance between pins
A (5 V) and H (SIG))
signal pin and GND pin. (See table 1).
(ex. For ST1, measure between pins H (SIG) and
G (GND))
4. Adjust resistance to be X = Y (tolerance: X Y
0.04 k) by slightly turning the potentiometer
body.
(Loosen screws (1) before adjusting)
5. Secure the potentiometer in place by tightening
screw (1).
Table 1
POTENTIOMETER No.
1
2
3
4
ST1
ST2
FR3
FR4
20-155-1
4
5V
A
M
L
O
PIN No.
SIG
GND
H
G
E
F
K
J
P
Q
D375A-5
D375A-5
20-155-2
4

1. Install the pre-adjusted PCCS lever to the machine.
(For details, see DISASSEMBLY OF PCCS LEVER.)
3. Turn key switch ON.
4. Check the voltage of each potentiometer (ST1, 2 & FR3, 4) by using the monitoring mode of the monitor
panel.
(For details, see SPECIAL FUNCTION OF MONITOR PANEL EMMS.)
5. Voltage should be 2,500 50 mV for each potentiometer.
ADJUSTING IN ATTACHED CONDITION
2. Using tester (4), adjust voltage by turning potentiometer slightly, so that the voltage becomes 2.5 V.
3. Tighten screw (2) at the position of voltage 2.5 V, and fix the potentiometer (1).
1. Potentiometer
5. T-adapter
2. Screw
6. Controller
3. PCCS lever
7. Machine power source
4. Tester
8. External power source (5 V)
20-155-3
4
A. Wiring connection of adjustment for machine

power source.
B. Wiring connection of adjustment for external
power source.
D375A-5

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

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

(11).
9. Loosen screw (9), then adjust voltage by turning
potentiometer (10) slightly.
ASSEMBLY
For assembly, procedure in reverse order.
20-155-5
4
D375A-5
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)
Special functions are displayed

portion
1. Speed range display portion
2. Service meter display portion
Special functions control portion 1

(basic control)
3. Service switch
4. Buzzer cancel switch
5. Economy mode switch
EMMS: Equipment Management Monitoring System
20-156
(5)
1
Special functions control portion 2

(switch control)
6. Slow reverse mode switch
7. SSC (Shoe Slip Control) switch
8. Bedrock selection switch
9. Auto shift down switch
10. Shift up switch
11. Shift down switch
D375A-5
OPERATION AND DISPLAY OF OPERATOR MODE (OUTLINE)

This section gives only an outline of the operator
mode.
For details of each function and mode and the
method of operation, see the Operation and
Maintenance Manual.
1. Normal display (default)
When the condition of the machine is normal, the
monitor panel displays the following information.
Speed range display (1):
Left side: Direction (P, N, F, R)
Right side: Speed range (1, 2, 3)
Bottom: Shift mode (!lamp)
Graphics: Engine speed
Service meter display (2):
Service meter (in units of 0.1h)
2. User code display function

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

User code
Method of displaying abnormality
Nature of abnormality
Only user code is displayed Torque converter does not lock up

Blade dual tilt does not work
Automatic functions stop or some

functions stop, but operation is possible
Please contact your Komatsu distributor for repairs
User code is displayed

Warning lamp flashes
Alarm buzzer sounds
Does not shift up or down

Blade pitch does not work
Engine stops but it is possible to start

it again and carry out operations
without limit. However, care must be
taken by user

Alarm buzzer sounds
Abnormality in engine water temper- Move to a safe place

ature sensor
Please contact your Komatsu distrib Available speed ranges are limited
utor for repairs
Engine does not rise to full speed
Excessive transmission shock
Difficult to turn (steer)
Excessive shock when braking

Alarm buzzer sounds
Engine control impossible

Travel impossible
Machine stops
E01
E02
CALL 03
CALL
D375A-5
Action recommended to operator
Stop machine immediately

20-159
1
OPERATION AND DISPLAY OF SERVICE

MODE
Method of switching to service mode
When using the service mode, carry out the following special operation to switch the screen display.
1) Special operation of switches
Set service switch (3) to the ON position, then
hold buzzer cancel switch (4) at the ON position
for at least 7 seconds.
The mode displayed on the panel differs according to the selection position of the economy mode switch (see next section).
2) Selecting mode to use
After switching to the service mode, operate the
following switches to switch to the mode to be
used.
Economy mode switch (5)
Economy mode
Mode
F1-R2 F2-R2
lamp lamp
OFF
Monitoring mode
Adjustment mode
Service code display mode
When switching to each mode, the shift

mode display lamp lights up or goes out to indicate which mode is now being used.
The economy mode switch can be set to the
position to be used before switching to the
service mode.
The diagram on the right shows the initial
screen when the economy mode switch is
OFF and the monitoring mode has been selected.
3) Finishing mode, function
When the service switch is turned OFF, the
mode or function can be finished regardless of
the mode or level being operated.
20-160
(5)
1
D375A-5
3. Monitoring mode
In the monitoring mode, it is possible to check
the condition of various parts of the machine on
the monitor panel according to the signals from
the sensors installed to various parts of the machine.
1) Selecting mode
Switch to the service mode and select the monitoring mode with the economy mode switch.
Economy mode switch (5): OFF
2) Content of display
In the monitoring mode, the following information
is displayed on the monitor panel.
Speed range display (1): Monitoring code
Service meter display (2): Monitoring data
For details of the code and data, see TABLE
OF MONITORING MODES.
3) Method of selecting monitoring code
There are the following three methods of selecting the monitoring code, so operate the
mode that is easiest to use.
i) Method of scrolling code forward or in reverse
The monitoring codes are in the internally
set order.
If the following switches are operated, the
codes are scrolled forward or in reverse in
the internally set order, so scroll to the code
to be selected.
Slow reverse mode switch (6): Scroll forward
Buzzer cancel switch (4): Scroll in reverse
When the system is switched to the monitoring mode, the 1st code is displayed.
For details of the order of the codes, see
TABLE OF MONITORING MODES.
D375A-5
20-161
(5)
1
ii) Method of block jump + scrolling forward and

in reverse
The monitoring codes are divided into 5
blocks internally according to the type of data.
screen will jump to the 1st code of each
block, so scroll forward or in reverse to select
the code from the lock.
SSC switch (7): Go to next block
When the system is switched to the monitoring mode, block 1 is displayed.
The blocks jump in the following order
(for details, see TABLE OF MONITORING CODES).
1
Steering system
38 items
Transmission system
27 items
Work equipment system
13 items
Engine system
Monitor panel system
9 items
15 items
iii) Method of inputting code

The monitoring codes are set internally as 2digit alphanumerical codes.
codes in the speed range display (left, right)
change, so input the code to be used.
Bedrock selection switch (8)
Left switch: Left code changes
Right switch: Right code changes
The left and right codes change in the
following order according to the operation of the switches (letters which are not
used for any code are jumped).
9AbCdEFHJLN
oPRU0123456
789
20-162
(5)
1
D375A-5
4) Hold function for monitoring data

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

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

Order
Code
Content of display
Unit
Controller
1 Steering system
1
99
Engine speed
rpm
Steering controller
91
Value of voltage for engine speed sensor
mV
Steering controller
7o
Transmission speed
rpm
Steering controller
93
Value of voltage for transmission speed sensor
mV
Steering controller
7R
Torque converter speed
rpm
Steering controller
95
Value of voltage for torque converter speed sensor
mV
Steering controller
bA
Battery voltage value
mV
Steering controller
L1
Value of voltage for steering potentiometer 1
mV
Steering controller
L2
Value of voltage for steering potentiometer 2
mV
Steering controller
10
L7
Value of voltage for brake potentiometer
mV
Steering controller
11
A6
Tilt angle
0.001
Steering controller
12
A8
Value of voltage for tilt angle sensor
mV
Steering controller
13
F5
Fuel control dial command speed
rpm
Steering controller
14
F6
Value of voltage for fuel control dial
mV
Steering controller
15
d5
Deceleration potentiometer command speed
rpm
Steering controller
16
d6
Value of voltage for deceleration potentiometer
mV
Steering controller
17
A5
Value of voltage for acceleration sensor
mV
Steering controller
18
5U
SSC command speed
rpm
Steering controller
19
5d
Value of voltage for engine command
mV
Steering controller
20
L9
Steering controller switch input 1
(bit)
Steering controller
21
LE
(bit)
Steering controller
22
LL
Steering controller oil pressure switch input 3
(bit)
Steering controller
23
CE
Steering controller HPI input 4
(bit)
Steering controller
24
LF
(bit)
Steering controller
25
LJ
(bit)
Steering controller
26
7b
Steering fill switch input
(bit)
Steering controller
27
P1
Value of voltage for left brake ECMV output command
mA
Steering controller
28
c1
Value of voltage for left brake ECMV output FB
mA
Steering controller
29
P2
Value of voltage for right brake ECMV output command
mA
Steering controller
30
c2
Value of voltage for right brake ECMV output FB
mA
Steering controller
31
P3
Value of voltage for left clutch ECMV output command
mA
Steering controller
32
c3
Value of voltage for left clutch ECMV output FB
mA
Steering controller
33
P4
Value of voltage for right clutch ECMV output command
mA
Steering controller
34
c4
Value of voltage for right clutch ECMV output FB
mA
Steering controller
35
58
Steering controller output
(bit)
Steering controller
36
d5
Value of voltage for sudden stop prevention solenoid drive
mV
Steering controller
37
d8
Value of voltage for engine controller relay drive
mV
Steering controller
38
dA
Value of voltage for battery relay drive
mV
Steering controller
: Code for PCCS lever potentiometers.
20-164
(7)
1
D375A-5
Order
Code
Content of display
Unit
Controller
2 Transmission system
39
3E
Engine speed
rpm
40
92
Value of voltage for engine speed sensor
mV
41
7P
Transmission speed
rpm
42
94
Value of voltage for transmission speed sensor
mV
43
A7
Tilt angle
0.001
44
A9
Value of voltage for tilt angle sensor
mV
45
L3
Value of voltage for directional potentiometer 1
mV
46
L4
Value of voltage for directional potentiometer 2
mV
47
L5
Transmission controller switch input 1
(bit)
48
L8
Transmission controller switch input 2
(bit)
49
7H
Transmission fill switch input
(bit)
50
P5
Value of voltage for FORWARD clutch ECMV (E-POCV) output command
mA
51
c5
Value of voltage for FORWARD clutch ECMV (E-POCV) output FB
mA
52
P6
Value of voltage for REVERSE clutch ECMV (E-POCV) output command
mA
53
c6
Value of voltage for REVERSE clutch ECMV output FB
mA
54
P7
Value of voltage for 1st clutch ECMV output command
mA
55
c7
Value of voltage for 1st clutch ECMV output FB
mA
56
P8
Value of voltage for 2nd clutch ECMV output command
mA
57
c8
Value of voltage for 2nd clutch ECMV output FB
mA
58
P9
Value of voltage for 3rd clutch ECMV output command
mA
59
c9
Value of voltage for 3rd clutch ECMV output FB
mA
60
Ld
Transmission controller output
(bit)
61
dL
Value of voltage for lock-up solenoid drive
mV
62
db
Value of voltage for back-up alarm relay drive
mV
63
dN
Value of voltage for neutral safety relay drive
mV
64
d1
(Not used)
65
d2
(Not used)
3 Work equipment system

66
bd
Blade lever knob switch input
(bit)
67
bH
Blade lever oil pressure switch input
(bit)
68
57
Transmission controller toggle switch input
(bit)
69
HL
Front pump oil pressure
70
4L
Value of voltage for front pump oil pressure sensor
kg/cm
2
mV
kg/cm
71
H5
Center pump oil pressure
72
45
Value of voltage for center pump oil pressure sensor
mV
73
56
Transmission controller solenoid drive status
(bit)
74
d3
Value of voltage for blade pitch solenoid drive
mV
75
d4
Value of voltage for blade dual solenoid drive
mV
: Code for PCCS lever potentiometers.
D375A-5
20-165
(7)
1
Order
Code
Content of display
Unit
Controller
76
Fc
(Not used)
77
FF
(Not used)
78
R7
Ripper lever oil pressure switch input
(bit)
4 Engine system
79
60
Deceleration pedal speed
rpm
Engine controller
80
61
Engine No. 2 throttle speed
rpm
Engine controller
81
62
Engine speed
rpm
Engine controller
82
63
Engine controller
83
64
(Not used)
84
65
Engine oil pressure
85
66
Fuel consumption ratio
86
67
Fuel temperature
87
68
Fuel consumption amount
kPa
Engine controller
0.1/h
Engine controller
Engine controller
Engine controller
5 Monitor panel system

88
U2
Monitor panel (tachometer) program No.
Numeral Monitor panel (tachometer)
89
U3
Transmission controller program No.
Numeral Transmission controller
90
U4
Monitor panel (caution) program No.
Numeral Monitor panel (caution)
91
U5
Steering controller program No.
Numeral Steering controller
92
5N
S-NET communication connection status
93
78
94
(bit)
Steering controller
(Not used)
Steering controller
77
Torque converter oil temperature
Steering controller
95
FL
Value of voltage for fuel level sensor
mV
Steering controller
96
Bu
Travel speed (theoretical value)
m/h
Steering controller
97
FR
Drawbar pull (theoretical value)
m(F/W)
Steering controller
98
C5
Steering status code
HEX
Steering controller
99
CF
Fill condition setting variable
HEX
Steering controller
100
Cb
Modulation condition setting variable
HEX
Steering controller
101
Cc
Gearshift point setting variable
HEX
Steering controller
102
5F
Slip flag
(bit)
Steering controller
Order for scrolling forward and in reverse when selecting code:

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

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

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

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

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

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

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

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

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

: (Not used)
: (Not used)
: (Not used)
: Engine controller drive relay output: Output
: Battery relay drive output: Output
: Emergency stop prevention solenoid relay drive
output: Output

L5: Transmission controller switch input 1

: Shift up switch OFF
: Shift up switch ON
: Shift down switch OFF
: Shift down switch ON
: Parking lever switch FREE
: Parking lever switch LOCK

L8: Transmission controller switch input 2

: Auto shift down switch ON
: (Not used)
: (Not used)
: (Not used)
: Service switch ON
: (Not used)

7H: Transmission fill switch input

: F clutch fill switch ON
: R clutch fill switch ON
: 1st clutch fill switch ON
: 2nd clutch fill switch ON
: 3rd clutch fill switch ON
: (Not used)

D375A-5
20-169
Ld: Transmission controller output

: (Not used)
: (Not used)
: (Not used)
: Backup alarm relay drive output: Output
: Neutral safety relay drive output: Output
: Lock-up solenoid drive output: Output

bd: Blade lever knob switch input

: Blade lever tilt switch: Dual
: Blade lever tilt switch: Single
: Blade lever pitch switch OFF
: Blade lever pitch switch ON
: (Not used)
: (Not used)

bH: Blade lever oil pressure switch input

: (Not used)
: (Not used)
: (Not used)
: (Not used)
: Blade tilt left oil pressure switch ON (operated)
: Blade tilt right oil pressure switch ON (operated)

57: Transmission controller toggle switch input

: Auto shift down switch ON
: (Not used)
: (Not used)
: (Not used)
: (Not used)
: (Not used)

20-170
D375A-5
56: Transmission controller solenoid drive status

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

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

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

1: (Not used)
2: (Not used)
3: (Not used)
4: (Not used)
5: (Not used)
6: (Not used)
D375A-5
20-171
1
4. Adjustment mode
In the adjustment mode, it is possible to check
the status and carry out adjustment of the machine controller and various equipment.
1) Selecting mode
Switch to the service mode, then use the economy mode switch to select the adjustment mode.
Economy mode switch (5): 1
2) content of display
In the adjustment mode, the following information is displayed on the monitor panel.
Speed range display (1): Adjustment mode
Service meter display (2): Related data
For details of the code and related data, see
TABLE OF ADJUSTMENT MODES AND
ADJUSTMENT PROCEDURE.
3) Selecting adjustment mode
In the adjustment mode, there is a fixed order for
the internal settings.
When the following switch is pressed, the code
will scroll forward in the order set internally, so
the code to use is displayed.
for details of the order for the adjustment
mode, see TAB LE O F ADJUSTMENT
MODES AND ADJUSTMENT PROCEDURE.
The code cannot be scrolled in reverse, so if
you go past the code to be used, it is necessary to continue scrolling forward for one cycle, or to switch to another mode and then
enter the adjustment mode again.
4) Switches and buzzers used in adjustment mode
Buzzer cancel switch (4): Confirmation function
Auto shift down switch (9): Selection function
Shift up switch (10): Increase value (oil pressure only)
Shift down switch (11): Decrease value (oil
pressure only)
When the confirmation operation of the
buzzer cancel switch is recognized, the
alarm buzzer will sound once.
20-172
(5)
1
D375A-5
1 AF: Transmission manual mode

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

This code is the function to adjust the right brake
oil pressure manually.
further.).
The maximum permitted range for adjustment is kg/cm2 (display: 300).
remains effective.
20-182
(5)
1
D375A-5
G PE: Steering clutch automatic adjustment

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

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

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

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

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

This code is the function to check the transmission F clutch learning control value and to format
the learning control value (all clutches).
The service meter display shows control value control value (unit: 10 ms).
Method of checking
When the code is selected, the following data are
displayed for 2 seconds.
Speed range Service meter display (Engine condition)
display
F1
F2
F3
F4
Control value H1 Low

control value L1
Control value H2 - Medium (low speed)
control value L2
Control value H3 Medium
control value L3
(high speed)
Control value H4 High speed
control value L4
Control value Hx: Control value (unit: 10 ms)

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

This code is the function to check the transmission R clutch learning control value and to format
the learning control value (all clutches).
Method of checking
display
R1
R2
R3
R4

control value L1
control value L2
control value L3
(high speed)
control value L4

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

This code is the function to check the transmission 1st clutch learning control value and to format the learning control value (all clutches).
Method of checking
display
11
12
13
14

control value L1
control value L2
control value L3
(high speed)
control value L4

N 2x: Transmission 2nd clutch trigger compensation value

This code is the function to check the transmission 2nd clutch learning control value and to format the learning control value (all clutches).
The service meter display shows the control value - control value (unit: 10 ms).
Method of checking
When the code is selected, the following data is
display
21
22
23
24

control value L1
control value L2
control value L3
(high speed)
control value L4

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

This code is the function to check the transmission 3rd clutch learning control value and to format the learning control value (all clutches).
The service meter display shows the control value - control value (unit: 10 ms).
Method of checking
When the code is selected, the following data is
display
31
32
33
34

control value L1
control value L2
control value L3
(high speed)
control value L4

P Pb: Steering brake I-P

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

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

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

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

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

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

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

In the service code display mode, any problem
that has occurred inside the system can be displayed as a service code.
1) Selecting mode
Switch to the service mode and operate the
economy mode switch to select the service code
display mode.
Economy mode switch (5): 2
2) Content of display
Speed range display (1):
Order of occurrence (recorded up to a
maximum of 20 items)
Service meter display (2):
Service code and service meter reading
for time of occurrence are displayed in
turn
Letter at head of service code
E: Code for problem detected at present
P: Code for problem not detected at present
Conditions for detecting and holding service
code
For service codes other than S-NET, if a
problem is detected, the [E] display continues until the starting switch is turned OFF. If
the starting switch is turned OFF and then
turned ON again or the engine is started, the
[P] display is held until the same problem is
detected again.
For the S-NET related service codes, even if
the starting switch is not turned OFF, the display changes to the [P] display immediately
the problem is removed.
3) Operation when multiple codes are recorded
If multiple codes are recorded, operate the following switch to display the codesin the order of
occurrence.
(order of occurrence)
The service code cannot be scrolled in reverse.
4) Deleting code
Display the code to be deleted, then operate the
following switch to delete the code.
Buzzer cancel switch (4): ON (delete)
Only the codes headed by [P] can be deleted; the codes headed by [E] cannot be deleted.
20-192
(5)
1
D375A-5
TABLE OF SERVICE CODES

Service
code
Controller
User
code
Warning
lamp
Alarm
buzzer
S/T
CALL03
MON
CALL03
E0101
Abnormality in network system (steering system)
E0104
Abnormality in network system (monitor panel system)
E0105
Abnormality in network system (steering system)
S/T
CALL03
E0111
Abnormality in steering controller power source system
S/T
CALL
E0112
Abnormality in transmission controller power source system
T/M
CALL
E0120
Short circuit in warning lamp system
MON
CALL03
E0121
Short circuit in alarm buzzer system
MON
CALL03
E0142
Abnormality in transmission controller 5V power source system
T/M
CALL03
E0143
Abnormality in steering controller 5V power source system
S/T
CALL03
E0145
Abnormality in steering controller 24V power source system
S/T
CALL03
E0146
Abnormality in transmission controller 24V power source system
T/M
E01
E0151
Abnormality in steering controller specification selection
S/T
CALL
E0152
Abnormality in network system (steering controller)
S/T
CALL03
E0160
Abnormality in transmission controller ROM
T/M
E01
E0161
Abnormality in steering controller ROM
S/T
E02
E0164
Abnormality in network system (transmission controller)
T/M
CALL03
E0176
Disconnection in battery relay system
S/T
E0177
Short circuit in battery relay system
S/T
E0178
Disconnection in neutral safety relay system
T/M
E02
E0179
Short circuit in neutral safety relay system
T/M
E02
E0211
Abnormality in torque converter oil temperature
MON
E0212
Short circuit in torque converter lock-up solenoid system
T/M
E01
E0213
Disconnection in torque converter lock-up solenoid system
T/M
E01
E0221
Disconnection, short circuit in tilt angle sensor system
T/M
E01
E0225
Slippage of power train clutch
T/M
E02
E0230
Simultaneous abnormality in directional potentiometer system (1)
T/M
CALL
E0231
T/M
CALL
E0232
T/M
CALL
E0233
Disconnection, short circuit in directional potentiometer 1 system
T/M
CALL03
E0234
Disconnection, short circuit in directional potentiometer 2 system
T/M
CALL03
E0235
Divergence of directional potentiometer system signal
T/M
CALL03
E0236
Disconnection, short circuit in shift up switch system
T/M
E02
E0237
Disconnection, short circuit in shift down switch system
T/M
E02
E0238
Disconnection, short circuit in parking lever switch system
T/M
CALL03
E0239
Mismatch in parking lever switch system signals
T/M
CALL03
E0250
Disconnection in transmission FORWARD clutch ECMV system
T/M
CALL03
E0251
Short circuit in transmission FORWARD clutch ECMV system
T/M
CALL03
E0252
Disconnection in transmission REVERSE clutch ECMV system
T/M
CALL03
D375A-5
20-193
(7)
1
Service
code
Controller
User
code
Warning
lamp
Alarm
buzzer
E0253
Short circuit in transmission FORWARD clutch ECMV (E-POCV) system
T/M
CALL03
E0254
Disconnection in transmission 1st clutch ECMV (E-POCV) system
T/M
CALL03
E0255
Short circuit in transmission 1st clutch ECMV (E-POCV) system
T/M
CALL03
E0256
Disconnection in transmission 2nd clutch ECMV (E-POCV) system
T/M
CALL03
E0257
Short circuit in transmission 2nd clutch ECMV (E-POCV) system
T/M
CALL03
E0258
Disconnection in transmission 3rd clutch ECMV (E-POCV) system
T/M
CALL03
E0259
Short circuit in transmission 3rd clutch ECMV (E-POCV) system
T/M
CALL03
E0260
Defective engagement of transmission FORWARD clutch
T/M
CALL03
E0261
Defective disengagement of transmission FORWARD clutch
T/M
CALL03
E0262
Defective engagement of transmission REVERSE clutch
T/M
CALL03
E0263
Defective disengagement of transmission REVERSE clutch
T/M
CALL03
E0264
Defective engagement of transmission 1st clutch
T/M
CALL03
E0265
Defective disengagement of transmission 1st clutch
T/M
CALL03
E0266
Defective engagement of transmission 2nd clutch
T/M
CALL03
E0267
Defective disengagement of transmission 2nd clutch
T/M
CALL03
E0268
Defective engagement of transmission 3rd clutch
T/M
CALL03
E0269
Defective disengagement of transmission 3rd clutch
T/M
CALL03
E0270
Multiple failure in transmission clutch
T/M
CALL03
E0271
Multiple failure in transmission clutch
T/M
CALL
E0306
Short circuit in blade tilt right oil pressure switch system
T/M
E02
E0307
Short circuit in blade tilt left oil pressure switch system
T/M
E02
E0308
Short circuit in ripper RAISE oil pressure switch system
S/T
E0309
Short circuit in ripper LOWER oil pressure switch system
S/T
E0310
Short circuit in ripper TILT IN oil pressure switch system
S/T
E0311
Disconnection, short circuit in blade pitch switch system
T/M
E02
E0312
Disconnection, short circuit in blade tilt switch system
T/M
E01
E0321
Disconnection in blade dual tilt selection solenoid system
T/M
E01
E0322
Short circuit in blade dual tilt selection solenoid system
T/M
E01
E0323
Disconnection in blade pitch selection solenoid system
T/M
E02
E0324
Short circuit in blade pitch selection solenoid system
T/M
E02
E0329
Abnormal hydraulic oil temperature
E0364
Disconnection in front pump oil pressure sensor system
T/M
E0365
Short circuit in front pump oil pressure sensor system
T/M
E0366
Disconnection in center pump oil pressure sensor system
T/M
E0367
Short circuit in center pump oil pressure sensor system
T/M
E0405
Disconnection, short circuit in fuel control dial system
ENG
CALL03
E0430
Engine oil: Abnormal oil pressure
ENG
CALL
E0431
Abnormal radiator coolant level
MON
CALL
E0432
Radiator coolant: Overheating
MON
E01
E0486
Abnormality in transmission controller model selection
T/M
CALL
E0501
Disconnection, short circuit in acceleration sensor system
S/T
E01
E0610
Disconnection in backup alarm relay system
T/M
E01
20-194
(6)
1
MON
q
q
q
D375A-5
Service
code
Controller
User
code
E01
Warning
lamp
Alarm
buzzer
E0611
Short circuit in back-up alarm relay system
T/M
E0660
Disconnection in ACC signal drive relay system
S/T
E0661
Short circuit in ACC signal drive relay system
S/T
E0721
Disconnection, short circuit in tilt angle sensor system
S/T
CALL03
E0730
Simultaneous abnormality in steering potentiometer system (1)
S/T
CALL
E0731
S/T
CALL
E0732
S/T
CALL
E0733
Disconnection, short circuit in steering potentiometer 1 system
S/T
CALL03
E0734
Disconnection, short circuit in steering potentiometer 2 system
S/T
CALL03
E0735
Divergence in steering potentiometer system signal
S/T
CALL03
E0736
Disconnection, short circuit in brake potentiometer system
S/T
CALL03
E0750
Disconnection in right steering clutch ECMV system
S/T
CALL03
E0751
Short circuit in right steering clutch ECMV system
S/T
CALL03
E0752
Disconnection in left steering clutch ECMV system
S/T
CALL03
E0753
Short circuit in left steering clutch ECMV system
S/T
CALL03
E0754
Disconnection in right steering brake ECMV system
S/T
CALL
E0755
Short circuit in right steering brake ECMV system
S/T
CALL
E0756
Disconnection in left steering brake ECMV system
S/T
CALL
E0757
Short circuit in left steering brake ECMV system
S/T
CALL
E0760
Defective engagement of right steering clutch
S/T
CALL
E0761
Defective disengagement of right steering clutch
S/T
CALL
E0762
Defective engagement of left steering clutch
S/T
CALL
E0763
Defective disengagement of left steering clutch
S/T
CALL
E0764
Defective engagement of right steering brake
S/T
CALL
E0765
Defective disengagement of right steering brake
S/T
CALL
E0766
Defective engagement of left steering brake
S/T
CALL
E0767
Defective disengagement of left steering brake
S/T
CALL
E0779
Disconnection in sudden stop prevention solenoid system
S/T
CALL
E0780
Short circuit in sudden stop prevention solenoid system
S/T
CALL
E0781
Disconnection, short circuit parking lever switch system
S/T
CALL03
E0782
Mismatch of parking lever switch system signals
S/T
CALL03
E0930
Disconnection in engine speed sensor system
S/T
E01
E0931
T/M
E01
E0932
Disconnection in transmission speed sensor system
S/T
E01
E0933
T/M
E01
E1939
Abnormality in J1939 communication system
S/T
E01
EC111
Abnormality in engine controller memory
ENG
CALL
EC112
Abnormality in timing rail actuator
ENG
CALL
D375A-5
20-195
(7)
1
Service
code
Controller
User
code
Warning
lamp
Alarm
buzzer
EC113
Abnormality in timing rail actuator system current
ENG
CALL03
EC115
Abnormality in engine speed sensor 2 system
ENG
CALL
EC116
Abnormality in timing rail pressure sensor system high level
ENG
CALL
EC117
Abnormality in timing rail pressure sensor system low level
ENG
CALL
EC118
Abnormality in fuel pump pressure sensor system high level
ENG
CALL03
EC119
Abnormality in fuel pump pressure sensor system low level
ENG
CALL03
EC121
Abnormality in engine speed sensor 1 system
ENG
CALL03
EC122
Abnormality in boost pressure sensor system high level
ENG
E01
EC123
Abnormality in boost pressure sensor system low level
ENG
E01
EC131
Abnormality in throttle sensor system high level
ENG
CALL
EC132
Abnormality in throttle sensor system low level
ENG
CALL
EC133
Abnormality in remote throttle sensor system high level
ENG
CALL
EC134
Abnormality in remote throttle sensor system low level
ENG
CALL
EC135
Abnormality in engine oil pressure sensor system high level
ENG
CALL03
EC141
Abnormality in engine oil pressure sensor system low level
ENG
CALL03
EC143
Abnormal drop in engine oil pressure
ENG
EC144
Abnormality in water temperature sensor system high level
ENG
CALL03
EC145
Abnormality in water temperature sensor system low level
ENG
CALL03
EC151
Abnormal rise in water temperature
ENG
EC153
Abnormality in intake air temperature sensor system high level
ENG
CALL03
EC154
Abnormality in intake air temperature sensor system low level
ENG
CALL03
EC221
Abnormality in atmospheric pressure sensor system high level
ENG
CALL03
EC222
Abnormality in atmospheric pressure sensor system low level
ENG
CALL03
EC234
Abnormal overspeed
ENG
EC254
Abnormality in fuel shut-off valve system voltage
ENG
E01
EC259
Abnormality in fuel shut-off valve
ENG
CALL
EC261
Rise in fuel temperature
ENG
EC263
Abnormality in fuel temperature sensor system high level
ENG
CALL03
EC265
Abnormality in fuel temperature sensor system low level
ENG
CALL03
EC316
Abnormality in fuel pump actuator system current
ENG
CALL03
EC318
Abnormality in fuel pump actuator
ENG
CALL03
EC346
Abnormal engine controller power down
ENG
CALL03
EC384
Abnormality in preheater control system
ENG
CALL03
EC423
In-range abnormality in timing rail pressure sensor system
ENG
CALL03
EC441
Abnormality in battery voltage system low level
ENG
E01
EC442
Abnormality in battery voltage system high level
ENG
E01
EC451
Abnormality in fuel rail pressure sensor system high level
ENG
CALL
EC452
Abnormality in fuel rail pressure sensor system low level
ENG
CALL
20-196
1
D375A-5
Service
code
Controller
User
code
EC455
Abnormality in fuel rail actuator system current
ENG
CALL
EC467
Abnormality in timing rail actuator control
ENG
CALL03
EC468
Abnormality in fuel rail actuator control
ENG
CALL03
EC514
Abnormality in fuel rail actuator
ENG
CALL
EC554
In-range abnormality in fuel rail pressure sensor system
ENG
CALL03
Warning
lamp
z
z
z
z
z
Alarm
buzzer
z
z
z
z
z
Letter at head of service code

E: Code for problem detected at present
P: Code for problem not detected at present
The controller in the Controller column indicates the controller or monitor panel responsible for the system
check for the applicable code.
MON: Monitor panel
ENG: Engine controller
T/M: Transmission controller
S/T: Steering controller
D375A-5
20-197

PREPARATORY WORK WHEN TROUBLESHOOTING

ELECTRICAL SYSTEM

ELECTRICAL SYSTEM
When carrying out troubleshooting of the electric
circuits related to the monitor panel, engine controller, transmission controller, and steering controller, use the following procedure to expose the
applicable connector.
2. Engine controller
1) Remove engine left side cover (3).
1. Monitor panel
2) Remove 2 mounting bolts, then pull monitor
panel (2) out towards the operators seat.
2) Insert or connect the troubleshooting Tadapter to connector ECMA and connector

ECMB of engine controller (4).
The connectors are held by screws, so
loosen the screws before disconnecting.
When returning the connectors to their
original position, tighten the screws to
the specified torque.
3) Insert or connect the troubleshooting Tadapter to connector S01, connector S02,
connector S03, connector CN1, connector
CN2, and connector CN4 of the monitor panel.
20-198
1
Screw: 2.82 Nm {0.288 kgm}
D375A-5
3. Transmission controller
2) Insert or connect the troubleshooting Tadapter to connector TMCN1, connector

TMCN2, and connector TMCN3 of transmission controller (6).
If it is difficult to remove or install the connectors, remove the controller from the
floor frame when carrying out the operation.
D375A-5
Screw: 2.82 Nm {0.288 kgm}

ELECTRICAL SYSTEM
4. Steering controller
2) Insert or connect the troubleshooting Tadapter to connector NGICN1, connector

NGICN2, and connector NGICN3 of steering
controller (7).
If it is difficult to remove or install the connectors, remove the controller from the
floor frame when carrying out the operation.
Screw: 2.82 Nm {0.288 kgm}
20-199

PM CLINIC SERVICE
Pm CLINIC SERVICE
Model
Serial No
Service meter
D375A-5
User name
Date of clinic
Serviceman
Blade
Specifications
Rear attachment
Shoe width
Semi-U blade
U-blade
Dual tilt blade
Multi-shank ripper
Variable giant ripper
Counterweight
kg
610 mm
710 mm
810 mm
Operating conditions
Quarry, mine
Coal
Gold
Limestone
Construction
Construction,
civil engineering
Roads
Tunnels
Type of soil (specific gravity )

Rock
Gravel
Sand
Clay
Type of work
Dozing
Side cutting
Ripping
Travel
%
%
%
%
Existence of abnormalities
Oil, water level check
Engine coolant level
Engine oil level
Hydraulic oil level
Engine coolant temperature Max. range
When necessary
Damper case
(
Power train
Final drive
Ambient temperature
Power train oil temperature Max. range
Max.
Min.
Height above sea level

m
Operators opinion
Visual check results
Service code history

E
Content:
E
Content:
D375A-5
Content:
h
Content:
20-201
1

Pm-clinic
PM CLINIC SERVICE
measuring points for D375A-5 (1/3)
q 2.
q 1.
q 3.
q 5.
q 4.
Reference items of measurement procedure (Pages)

q1. Engine speed: Measuring engine speed (20-102 103 page)
q2. Blow-by pressure: Measuring blow-by pressure (20-112 page)
q3. Engine oil pressure: Measuring engine oil pressure (20-113 page)
q4. Boost pressure: Measuring intake air pressure (boost pressure) (20-104 page)
q5. Exhaust temperature: Measuring exhaust temperature (20-105 106 page)
20-202
(5)
1
D375A-5

Pm-clinic
PM CLINIC SERVICE
measuring points for D375A-5 (2/3)

q6. Items related to torque converter: Measuring power train oil pressure (20-123 131-1 page)
q7. Items related to transmission: Measuring power train oil pressure (20-123 131-1 page)
q8. Items related to steering: Measuring power train oil pressure (20-123 131-1 page)
D375A-5
20-203
(5)
1
203
Pm-clinic measuring points for D375A-5 (3/3)

q9. Items related to work equipment: Testing and adjusting work equipment oil pressure (20-140 142 page)
q10. Items related to work equipment: Testing and adjusting control circuit main pressure (20-143 144 page)
20-203-1
(5)
D375A-5
Pm CLINIC CHECK SHEET
D375A-5
Date
Work order No.
Serial
PMNoCLINIC SERVICE
Serviceman
Service meter
h
Item
Engine speed
Low idling
Deceleration pedal depressed
Decel
High idling
Unit
rpm
Torque converter stall + work equipment relief
Engine
Blow-by pressure
Engine oil
pressure
kPa
<mmAq>

SAE10W
kPa
<kg/cm2>
SAE15W-40 SAE30
Boost pressure
Exhaust temperature

kPa
<mmHq>
No. 1, 2 & 3
No. 4, 5 & 6
Standard value for new machine Service limit value Measurement results Pass Fail
690 - 750
850 - 950
1870 - 1930
1470 - 1570
690 - 750
850 - 950
1870 - 1930
1240 - 1360
Max. 4.9
<Max. 500>
Min. 100
<Min. 1.0>
340 - 540
<3.5 - 5.5>
Min. 120
<Min. 1.2>
380 - 590
<4.0 - 6.0>
Min. 107
<Min. 800>
Min. 1430
Min. 1160
Max. 7.9
<Max. 800>
50
<0.5>
180
<1.8>
70
<0.7>
210
<2.1>
Min. 93
<Min. 700>
Max. 680
700
When measuring the oil pressure of the torque converter and transmission, use the adjustment mode of the monitor and set to "Both steering clutches release mode (Co mode)".
(Check that the left and right steering clutches are released.) When measuring the pressure of each transmission clutch, check only with the engine at low idling to ensure safety.
Item
Unit
Standard value for new machine
Service limit value
MPa
<kg/cm2>
0.03 - 0.15
<0.3 - 1.5>
0.01 - 0.15
<0.1 - 1.5>
0-0
<0 - 0>
2.25 - 2.65
<23.0 - 27.0>
0.8 - 1.0
<8.0 - 10.0>
0.39 - 0.64
<4.0 - 6.5>
0-0
<0 - 0>
2.45 - 2.85
<25.0 - 29.0>
1.27 - 1.47
<13.0 - 15.0>
0-0
<0 - 0>
0.03 - 0.15
<0.3 - 1.5>
0.01 - 0.15
<0.1 - 1.5>
0-0
<0 - 0>
2.25 - 2.65
<23.0 - 27.0>
0.8 - 1.0
<8.0 - 10.0>
0.39 - 0.64
<4.0 - 6.5>
0-0
<0 - 0>
2.45 - 2.85
<25.0 - 29.0>
1.27 - 1.47
<13.0 - 15.0>
0-0
<0 - 0>
Unit
Standard value for new machine
Service limit value
2.40 - 2.70
<24.5 - 27.5>
2.55 - 2.85
<26.0 - 29.0>
2.35 - 2.94
<24.0 - 30.0>
2.45 - 2.94
<25.0 - 30.0>
0.15 - 0.25
<1.5 - 2.5>
2.40 - 2.70
<24.5 - 27.5>
2.40 - 2.70
<24.5 - 27.5>
2.05 - 2.45
<21.0 - 25.0>
2.40 - 2.70
<24.5 - 27.5>
2.40 - 2.70
<24.5 - 27.5>
0.15 - 0.25
<1.5 - 2.5>
2.35 - 2.94
<24.0 - 30.0>
2.35 - 2.94
<24.0 - 30.0>
1.96 - 2.55
<20.0 - 26.0>
2.35 - 2.94
<24.0 - 30.0>
2.35 - 2.94
<24.0 - 30.0>
Inlet oil pressure

Outlet oil pressure
Lock-up clutch pressure
Torque converter
Stator clutch pressure

Inlet oil pressure
Transmission:
Neutral
Oil temperature:
70-90
Outlet oil pressure

Transmission: F1
(Co mode)
Item
Raise engine speed,

when lock-up lamp
lights up
Transmission
Lubricating oil
pressure
F clutch pressure
R clutch pressure
1st clutch pressure
2nd clutch pressure
3rd clutch pressure
20-204
4
1

Transmission:
Neutral Engine at low idling
T/M: F3
(Co mode)
T/M: R3
(Co mode)
T/M: F1
(Co mode)
T/M: F2
(Co mode)
T/M: F3
(Co mode)

MPa
<kg/cm2>
Measurement results Pass Fail
Measurement results Pass Fail
D375A-5
Pm CLINIC CHECK SHEET
D375A-5
Date
Work order No
Serial
No
PM
CLINIC SERVICE
Serviceman
Service meter
h
Item
Unit
Left clutch pressure

Steering clutch & brake
Left brake pressure

Transmission:
Neutral
Left brake pressure
MPa
<kg/cm2>
Right clutch pressure

Right brake pressure
Transmission:
Neutral

Brake performance
Engine at high idling, F2, brake actuated

Item
Hydraulic components
Front pump
Ripper lift
relief
Center pump
Blade tilt relief

(single tilt only)
Front pump
Ripper lift
relief
Center pump
Engine at high
Blade tilt relief
(single tilt only) idling
Control circuit main

pressure
Neutral
Engine at low
idling
MPa
<kg/cm2>
q Pump oil pressure is standard value measured by monitor panel.

Blade RAISE
Single tilt (left
Dual tilt (left
g right)
g right)
Ripper tilt (in
g out)
Item
2.40 - 2.70
<24.5 - 27.5>
2.35 - 2.65
<24.0 - 27.0>
2.55 - 2.85
<26.0 - 29.0>
2.50 - 2.80
<25.5 - 28.5>
2.40 - 2.70
<24.5 - 27.5>
2.35 - 2.65
<24.0 - 27.0>
2.55 - 2.85
<26.0 - 29.0>
2.50 - 2.80
<25.5 - 28.5>
Min. 2.4
<Min. 24.0>
Min. 2.4
<Min. 24.0>
Min. 2.4
<Min. 24.0>
Min. 2.4
<Min. 24.0>
Min. 2.4
<Min. 24.0>
Min. 2.4
<Min. 24.0>
Min. 2.4
<Min. 24.0>
Min. 2.4
<Min. 24.0>
Machine must not move

18.6 - 20.6
<190 - 210>
Min. 17.6
<Min. 180>
18.6 - 20.6
<190 - 210>
Min. 17.6
<Min. 180>
19.6 - 21.6
<200 - 220>
Min. 18.6
<Min. 190>
19.6 - 21.6
<200 - 220>
Min. 18.6
<Min. 190>
4.22 - 4.80
<43 - 49>
Min. 3.9
<Min. 40>
When using an oil pressure gauge, see TESTING AND ADJUSTING STANDARD VALUES.
Item
Unit
Unit
Max.17
9 - 15
3.5 - 4.5
Max. 6
8 - 12
Max.16
Sec.
3-4
Max. 5
10 - 15
Max.16
4-5
Max. 6
8 - 12
Max.16
3-4
Max. 6
Unit
Hydraulic drift

Blade lift cylinder
Engine stopped
Max. 100
Max. 150
Max. 15
Max. 30
mm/5 min.
Item
Visual inspection of final drive drain plug
Unit
Engine stopped
There must be no excessive metal particles
Always fill in the record when repairing, adjusting, or replacing main parts.
Date
D375A-5
Service meter
Repair record
Date
Service meter
Repair record
20-205
(5)
1
TESTING AND
PmADJUSTING
CLINIC
UNDERCARRIAGE CHECK SHEET

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

Left side of machine
Measurement
results
Pass Fail
Measurement
results
Pass Fail
Right side of machine
Opening of track link
20-206
3
1
Left track
A: Clearance between links
Pin No.
1.4
Right track
A: Clearance between links
Pin No.
1.4
D375A-5
PM CLINIC SERVICE
UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)
(Program form No.: SELA195001)
Komatsu
Undercarriage Inspection
Customer name:
Address:
D375A-5
Model
Serial#
Location
Soil condition
Working condition
master
i
Shoe width (mm)
Inspector
Shoe type
(yyyy/m/d)
Wear
%
New
SMR
Hours on
Rebuilt Parts:
Wet
SINGLE
Wear type
NORMAL
Comments/Observation
RH 1121.2 1141.2
LH
master pin
Dealer
L=l/4
Work Order No
Wet,AR,HD or Dry
Insp.Date(yy/mm/dd)
New 100% Measured
Wear
mm
LH 1121.2 1141.2
LINK PITCH
Equip#
SMR
280.30 285.30
1.3
RH 280.30 285.30
LINK HEIGHT1.3
BUSHIN
G
d1
d
D is the smallest
ofd1,,d2 and,d3
LH
181.0
163.0
RH
181.0
163.0
LH
98.5
90.0
RH
98.5
90.0
LH
93.0
30.0
RH
93.0
210.0
30.0
185.0
210.0
210.0
185.0
185.0
210.0
23.5
185.0
36.0
23.5
23.5
36.0
36.0
LH
23.5
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
0.0
36.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
8.0
RH
0.0
8.0
New
Turned
New
Turned
GROUSER HIGHT
H
LH
CARRIER
CARRIER
Front
RH
LH
Rear
1.3
RH
LH
IDLER
IDLER
Front
RH
LH
Rear
1.3
TRACK ROLLER
D
h2
h1
D=2(h1-
1.3
SPROCKET
H is the smallest of
h1,h2,h3
h3
h1
h2
1.3
RH
1
LH
LH
LH
LH
LH
LH
LH
LH
LH
10
LH
RH
RH
RH
RH
RH
RH
RH
RH
RH
10
RH
Remarks:
D375A-5
20-207
(6)
1
PM CLINIC SERVICE
UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)
(Program form No.: SELA195001)
Komatsu
Undercarriage Inspection
Customer name:
Address:
D375A-5
Model
Serial#
Location
Soil condition
Working condition
master
i
Shoe width (mm)
Inspector
Shoe type
(yyyy/m/d)
Wear
%
New
SMR
Hours on
Rebuilt Parts:
Wet
SINGLE
Wear type
IMPACT
Comments/Observation
RH 1121.2 1133.2
LH
master pin
Dealer
L=l/4
Work Order No
Wet,AR,HD or Dry
Insp.Date(yy/mm/dd)
New 100% Measured
Wear
mm
LH 1121.2 1133.2
LINK PITCH
Equip#
SMR
280.30 283.30
1.3
RH 280.30 283.30
LINK HEIGHT1.3
BUSHIN
G
d1
d
D is the smallest
ofd1,,d2 and,d3
LH
181.0
163.0
RH
181.0
163.0
LH
98.5
92.5
RH
98.5
92.5
LH
93.0
30.0
RH
93.0
210.0
30.0
185.0
210.0
210.0
185.0
185.0
210.0
23.5
185.0
36.0
23.5
23.5
36.0
36.0
LH
23.5
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
270.0
0.0
36.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
200.0
8.0
RH
0.0
8.0
New
Turned
New
Turned
GROUSER HIGHT
H
LH
CARRIER
CARRIER
Front
RH
LH
Rear
1.3
RH
LH
IDLER
IDLER
Front
RH
LH
Rear
1.3
TRACK ROLLER
D
h2 h1
D=2(h1-
1.3
SPROCKET
H is the smallest of
h1,h2,h3
h3
h1
h2
1.3
RH
1
LH
LH
LH
LH
LH
LH
LH
LH
LH
10
LH
RH
RH
RH
RH
RH
RH
RH
RH
RH
10
RH
Remarks:
20-208
(6)
1
D375A-5
TROUBLESHOOTING
MON MODE RELATED ELECTRICAL CIRCUIT DIAGRAM
TROUBLESHOOTING
Points to remember when troubleshooting .............................................................................................. 20-302
Sequence of events in troubleshooting ................................................................................................... 20-303
Points to remember when carrying out maintenance .............................................................................. 20-304
Checks before troubleshooting ............................................................................................................. 20-307-5
Classification of and procedure for troubleshooting ................................................................................ 20-308
Connector allocation drawing and electrical circuit diagrams for each system ....................................... 20- 311
Connection table for connector pin numbers ........................................................................................... 20-330
T-Branch box and T-Branch table ............................................................................................................ 20-353
Troubleshooting when service code is displayed (Service code) ............................................................
Troubleshooting of electrical system (E-mode) .......................................................................................
Troubleshooting of hydraulic and mechanical system (H-mode) .............................................................
Troubleshooting of the engine body (S-mode) ........................................................................................
D375A-5
20-401
20-601
20-701
20-801
20-301
(7)
1
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING

Stop the machine in a level place, and check that the safety pin, blocks, and parking brake are securely fitted.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is hot, hot water may spurt out and cause burns, so wait for
the engine to cool down before starting troubleshooting.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing the plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to
prevent reoccurrence of the failure.
When carrying out troubleshooting, and important point is of course to understand the structure and function.
However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea
of possible causes of the failure that would produce the reported symptoms.
1.
2.
3.
When carrying out troubleshooting, do not hurry

to disassemble the components.
If components are disassembled immediately any
failure occurs:
Parts that have no connection with the failure or other unnecessary parts will be disassembled.
It will become impossible to find the cause

of the failure.
It will also cause a waste of manhours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior
investigation and to carry out troubleshooting in
accordance with the fixed procedure.
Points to ask user or operator
1) Have any other problems occurred apart from
the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure?
When were these repairs carried out?
6) Has the same kind of failure occurred before?
Check before troubleshooting
1) Check for symptoms of any abnormality in
the machine.
2) Check the CHECKS BEFORE STARTING items.
20-302
1
3)
4)
4.
5.
6.
Other inspection items.

Other maintenance items can be checked externally, so check any item that is considered
to be necessary.
Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
When operating the machine to reenact the
troubleshooting symptoms, do not carry out
any investigation or measurement that may
make the problem worse.
Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of
failure, then use the troubleshooting flowchart to
locate the position of the failure exactly.
The basic procedure for troubleshooting is
as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the problem occurred. Then, remove the root cause.
D375A-5
TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING

Office, shop
Jobsite
TEW00180
TEW00181
Step 1
Examination, confirmation of symptoms
1) When a request for repairs is received, first
ask the following points.
Name of customer
Type, serial number of machine
Details of jobsite, etc.
2) Ask questions to gain an outline of the problem.
Condition of failure
Work being carried out at the time of the
failure
Operating environment
Past history, details of maintenance, etc.
Step 2
Determining probable location of cause
1) Look at the troubleshooting section of the
shop manual to find locations of possible
causes.
Step
Repair at jobsite
Hurray !
It's repalred
Step 3
Preparation of troubleshooting tools
TEW00185
1) Look at the table of troubleshooting tools in

the shop manual and prepare the necessary
tools.
T-adapter
Hydraulic pressure gauge kit, etc.
2) Look in the parts book and prepare the necessary replacement parts.
Step 7
Pinpoint locations of failure (carry out
troubleshooting)
Decide action to take
TEW00186
1) Before starting troubleshooting, locate and

repair simple failures.
Check before starting items
Other check items
2) See the Troubleshooting Section of the shop
manual, select a troubleshooting flowchart
that matches the symptoms, and carry out
troubleshooting.
TEW00187
Step 6
Re-enacting failure
Step 4
Go to jobsite
Drive and operate the machine to confirm

the condition and judge if there is really a
failure.
Step 5
Ask operator questions to
failure.
TEW00189
confirm details of
Was there anything strange about the machine before the failure occurred?
Did the failure occur suddenly?
Had any repairs been carried out before the
failure?
TEW00190
D375A-5
20-303
TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE

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

ELECTRIC EQUIPMENT
1) Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wiring.
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.
TEW00191
Main failures occurring in wiring harness

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

The pins of the male and female connectors
are in contact at the crimped terminal or
soldered portion, but if there is excessive
force brought to bear on the wiring, the plating at the joint will peel and cause improper
connection or breakage.
20-304
1
D375A-5
TROUBLESHOOTING
3 Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with a
crane with the wiring still connected, or a
heavy object hits the wiring, the crimping of
the connector may separate, or the soldering may be damaged, or the wiring may be
broken.
TEW00194
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.
As already said, the connector is designed
to prevent water from entering, but at the
same time, if water does enter, it is difficult
for it to be drained. Therefore, if water should
get into the connector, the pins will be shortcircuited by the water, so if any water gets
in, immediately dry the connector or take
other appropriate action before passing electricity through it.
5 Oil or dirt stuck to connector
If oil or grease are stuck to the connector
and an oil film is formed on the mating surface between the male and female pins, the
oil will not let the electricity pass, so there
will be defective contact.
If there is oil or grease stuck to the connector, wipe it off with a dry cloth or blow it dry
with compressed air and spray it with a contact restorer.
When wiping the mating portion of the
connector, be careful not to use excessive force or deform the pins.
If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the
compressed air completely before cleaning with compressed air.
D375A-5
TEW00195
TEW00196
20-305
TROUBLESHOOTING
2) Removing, installing, and drying connectors and

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

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

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

Align the position of the connector correctly,
then insert it securely.
For connectors with lock stopper, push in
the connector until the stopper clicks into
position.
Correct any protrusion of the boot and any
misalignment of the wiring harness
For connectors fitted with boots, correct any
protrusion of the boot. In addition, if the
wiring harness is misaligned, or the clamp
is out of position, adjust it to its correct position.
If the connector cannot be corrected easily, remove the clamp and adjust the
position.
If the connector clamp has been removed,
be sure to return it to its original position.
Check also that there are no loose clamps.
TEW00200
TBW00487
Since the DT 8-pole and 12-pole heavy duty wire

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

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

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

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

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

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

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

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

HYDRAULIC EQUIPMENT
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit.
When adding hydraulic oil, or when disassembling or
assembling hydraulic equipment, it is necessary to
be particularly careful.
1) Be careful of the operating environment
Avoid adding hydraulic oil, replacing filters, or 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 equipment in the field, there is
danger of dust entering the equipment. It is also
difficult to confirm the performance after repairs,
so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic equipment
should be carried out in a specially prepared
dustproof workshop, and the performance
should be confirmed with special test equipment.
3) Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with
a rag, there is danger or dirt entering or of the
surrounding area being made dirty by leaking oil
so never do this.
Do not simply drain oil out on to the ground, collect it and ask the customer to dispose of it, or
take it back with you for disposal.
4) Do not let any dirt, or dust get in during refilling operations.

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

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

Hydraulic,
Electrical
mechanical equipment
equipment
Action
Check fuel level
Add fuel
2.
Check for impurities in fuel
Clean, drain
3.
Check hydraulic oil level
Add oil
4.
Check oil level in damper case
Add oil
5.
Check power train oil level
Add oil
6.
Check engine oil level (engine oil pan level)
Add oil
7.
Check coolant level
Add water
8.
Check dust indicator for clogging
Clean or replace
9.
Check travel of brake pedal
Adjust
10. Check for looseness, corrosion of battery terminal, wiring
Tighten or replace
11. Check for looseness, corrosion of alternator terminal, wiring
Tighten or replace
12. Check for looseness, corrosion of starting motor terminal, wiring
Tighten or replace
13. Check for abnormal noise, smell
Repair
14. Check for oil leakage
Repair
15. Carry out air bleeding
Bleed air
20 - 30 V
Replace
17. Check battery electrolyte level
Add or replace
18. Check for discolored, burnt, exposed wiring
Replace
19. Check for missing wiring clamps, hanging wire
Repair
20. Check for water leaking on wiring (pay particularly careful attention
to water leaking on connectors or terminals)
Disconnect connector
21. Check for water on wiring

22. Check alternator voltage (engine running at 1/2 throttle or above)
23. Check operating sound of battery relay (starting switch ON, OFF)
20-307-5
4
Judgement
Value
1.
16. Check battery voltage (engine stopped)
Electrical equipment
Other check items
Checks before starting
Item
and dry
Replace
After running for

several minutes:
27.5 - 29.5 V
Replace
Replace
D375A-5
TROUBLESHOOTING
CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING
CLASSIFICATION OF AND PROCEDURE FOR

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

If a possible fault is detected in the machine, narrow the troubleshooting Nos. according to the following procedure, then go to the related troubleshooting section.
1. Procedure for troubleshooting when user code is displayed on monitor panel:
If a user code is displayed on the monitor panel, display the service code in the service code display mode
of the monitor panel (EMMS).
Carry out the troubleshooting for the displayed "service code".
The service code becomes "E" when a fault is detected. Accurately, even if it is "P" when the starting
switch is turned ON, the fault may not have been repaired. (Some faults are detected by simply turning
the starting switch ON, however.)
If the service code is recorded, be sure to perform the procedure for reproducing it to see if the corresponding fault has been repaired. (For the method of reproducing the service code, see the troubleshooting for the service code.)
2. Procedure for troubleshooting when service code is recorded:
If a user code is not displayed on the monitor panel, check the service code in the service code display mode
of the monitor panel (EMMS).
If the service code is recorded, carry out the troubleshooting for that "service code".
The service code becomes "E" when a fault is detected. Accurately, even if it is "P" when the starting
switch is turned ON, the fault may not have been repaired. (Some faults are detected by simply turning
the starting switch ON, however.)
If the service code is recorded, be sure to perform the procedure for reproducing it to see if the corresponding fault has been repaired. (For the method of reproducing the service code, see the troubleshooting for the service code.)
3. Procedure for troubleshooting when user code is not displayed and service code is not recorded
If a service code is not recorded on the monitor panel (EMMS), the machine may have a fault in its electric,
hydraulic, or mechanical system and may not able to detect it by the self-diagnosis.
In this case, check the possible fault again and select the related faults from the table of "Possible faults and
troubleshooting Nos. for them" and carry out troubleshooting for the related items in the "E mode", "H mode"
or "S mode".
20-308
(5)
1
D375A-5
TROUBLESHOOTING
Phenomena considered to be failures and troubleshooting No.

No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
Phenomena considered to be failures
Troubleshooting
Service code
User code, service code related

User code is displayed on monitor panel
Service code is displayed in service code display mode
!
Engine related
Engine starting is poor (always takes time to start)
Engine does not turn
Engine turns but no exhaust
Engine does not start
smoke comes out
Exhaust smoke comes out but
engine does not start
Engine pickup is poor (response is poor)
Engine stops during operation
Engine turns irregularly (hunting)
Lack of output or no power
Exhaust color is black (incomplete combustion)
Oil consumption is excessive or exhaust color is blue
Oil quickly becomes dirty
Fuel consumption is excessive
Oil mixed in cooling water, blows back, water level goes down
Oil level rises
There is abnormal noise
Excessive vibration
Preheating does not work
Power train related
No power (no drawbar pull)
Does not travel (when in 2nd or 3rd)
Does not move off in any speed range
Moves in only one direction (forward or reverse)
Excessive time lag when shifting gear or shifting between
forward and reverse
Cannot turn (steering)
Turns in only one direction (steering)
Overruns when turning (steering)
Brakes do not work
Torque converter does not lock up
Torque converter oil overheats
Work equipment related
All work equipment speeds are slow
No work equipment moves
Blade RAISE speed is slow or lacks power
Blade LOWER speed is slow or lacks power
Ripper RAISE speed is slow or lacks power
Ripper LOWER 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
Blade pitch does not work
Abnormal noise from around hydraulic pump
D375A-5
E mode
H mode
S mode
Check service code
S-1
S-2 1)
E-1
S-2 2)
S-2 3)
S-3
S-4
S-5
S-6
S-7
S-8
S-9
S-10
S-11
S-13
S-15
S-16
E-2
H-1
H-2
H-3
H-4
S-6
H-5
H-6
H-7
H-8
H-9
H-10
H-11
E-3
H-12
H-13
H-14
H-15
H-16
H-17
H-18
H-19
H-20
H-21
H-22
H-23
20-309
(5)
1
TROUBLESHOOTING
No.
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
Phenomena considered to be failures
Troubleshooting
Service code
E mode
H mode
S mode
Monitor panel related (operator mode: normal screen)

Nothing lights up on monitor panel when starting switch is
E-4
turned ON
All lamps on monitor panel stay on and do not go out when
E-5
starting switch is turned ON
Basic check items flash when starting switch is turned ON
E-6
Caution items flash when engine is running
E-7
Warning items flash when engine is running
E-8
Preheating lamp does not light up
E-9
Engine water temperature gauge display is not normal
E-10
Torque converter oil temperature gauge display is not normal
E-11
Fuel gauge display is not normal
E-12
Travel speed, engine speed, shift mode display is not normal
E-13
Service meter display is not normal
E-14
Switch module cannot be operated
E-15
Warning lamp does not flash or does not go out
E-16
Alarm buzzer does not sound or does not stop
E-17
Alarm buzzer cannot be canceled
E-18
Monitor panel related (service mode: special for function screen)
Does not switch to service mode
E-19
Others
Backup alarm does not sound
E-20
Panel night lighting, front lamp, working lamp, rear lamp do
E-21
not light up
Air conditioner does not work
E-22
20-310
(5)
1
D375A-5
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL

CIRCUIT DIAGRAMS FOR EACH SYSTEM
TROUBLESHOOTING

TABLE OF CONNECTORS
Conne
ctor
No.
101
1939
201
202
203
204
205
206
206
212
214
215
216
217
218
219
221
223
224
241
242
243
244
262
263
264
265
266
351
360
369
375
405
422
423
431
452
453
653
701
702
703
Connecto No. of
r type
pins
18-14
DT
DT
DT
DT
Terminal
DT
Terminal
DT-B
DT-C
DT-D
DT
DT
DT
DT
DT
DT
DT
DT
X
X
DT
Terminal
Terminal
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
Terminal
Terminal
Terminal
D375A-5
14
9
4
4
2
2
1
4
3
12
12
12
2
4
4
2
2
2
12
2
2
2
2
2
4
1
1
2
6
6
4
2
2
2
3
2
2
2
1
1
1
Place of use
Intermediate connector (Engine side connector No. VHL)
Engine controller communication connector

Intermediate connector
Right front lamp
Left front lamp
Horn
GND
Buzzer cancel switch
Alarm buzzer
Rear lamp switch
Front lamp & working lamp switch
Left working lamp
Left rear lamp
Ripper pin-puller solenoid valve
Right working lamp
Right rear lamp
Backup alarm
Horn switch
Ripper pin-puller switch
Horn switch
Horn switch
Air conditioner compressor
Window washer motor (left rear)
Window washer motor (right front)
Warning lamp
Radiator water level switch
Fuel level sensor
Hydraulic oil temperature sensor
Torque converter oil temperature sensor
Torque converter lock-up solenoid valve
Battery relay terminal BR
Battery relay terminal M
Battery relay terminal B
Address
3-dimensional
M circuit E circuit T circuit S circuit
drawing
F-1
H-7
G-2
I-4
I-8
C-1
C-1
J-8
A-4
K-8
A-5
K-9
D-1
K-8
B-2
E-1
J-7
N-4
L-3
N-6
B-2
F-8
N-3
C-8
D-7
N-2
C-7
E-7
N-2
C-3
K-6
F-7
D-7
P-1
B-3
N-5
B-2
N-6
B-2
G-2
I-8
J-4
I-8
I-3
D-8
E-8
J-8
A-5
E-8
J-9
J-9
K-9
Q-8
R-8
R-8
Y-3
K-5
J-4
N-5
B-2
K-5
I-4
K-8
e-5
h-3
e-5
B-3
K-9
I-8
I-8
J-8
E-8
F-8
G-3
K-8
20-311

TROUBLESHOOTING
The address shows the approximate position in the connector 3-dimensional allocation drawing and the circuit diagrams for each system
Conne
Connecto No. of
ctor
r type
pins
No.
1-pin
800
1
connector
1-pin
801
1
connector
AAPR
3
ADH
4
ARC
X
2
ASD
4
BB1
5
BB2
5
BB3
5
BKA
5
BRK
DT
3
CAN
12
CAN
3
CB1
2
CB2
2
CB3
2
CB4
2
CB5
2
CB6
2
CLTP
2
CN1
AMP
12
CN2
AMP
8
CN4
M
2
1-pin
CN-1
1
connector
CN-2 Terminal
1
CN-3 Terminal
1
CN-4
4
CN-5 Terminal
1
CN-6 Terminal
1
CN-9
6
CN-10
9
CN-11
6
CN-12
6
CN-13
6
CN-14
6
CN-15
2
CN-17
4
CN-18
4
CN-19
M
4
CN-20
DT
1
CN-21
DT
1
CN-22 Terminal
2
CN-23
4
CN-24
2
1-pin
CN-25
1
connector
20-312
1
Place of use
Address
3-dimensional
drawing
Spare power source
N-9
Spare power source
N-9
Atmospheric pressure sensor

Heater switch
Air conditioner condenser
Auto shift down switch
Front lamp relay
Front lamp relay
Working lamp relay
Backup alarm relay
Brake potentiometer
CAN Terminal resistance
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Circuit breaker
Engine water temperature sensor
Monitor panel
Monitor panel
Monitor panel
C-8
N-4
H-3
N-4
M-8
M-7
M-8
M-8
Q-1
d-4
W-7
M-9
M-9
M-9
M-9
M-8
M-8
Y-6
O-7
P-7
O-6
Lamp outlet connector [cab]
H-9
Rear right speaker [cab]

Rear right speaker [cab]
Rear wiper motor [cab]
Rear left speaker [cab]
Rear left speaker [cab]
Front wiper motor [cab]
Radio [cab]
Left wiper switch [cab]
Front wiper switch [cab]
Right wiper switch [cab]
Rear wiper switch [cab]
Lamp switch [cab]
Right door wiper motor [cab]
Left door wiper motor [cab]
Cab power source connector [cab]
Cab power source connector [cab]
Cigar lighter [cab]
Converter [cab]
Intermediate connector [cab]
H-9
H-9
G-9
G-9
G-9
E-8
I-9
E-9
E-9
F-9
F-9
F-9
E-8
I-7
G-2
T-1
T-1
K-6
G-9
K-6
Rotating lamp outlet connector [cab]
I-9
G-8
F-8
H-1
I-1
I-3
D-8
E-8
K-6
F-1
L-3
I-2
J-1
J-1
J-1
J-3
K-3
A-6
A-5
A-6
H-1
L-5
F-8
H-2
I-2
E-9
D375A-5
TROUBLESHOOTING
Conne
ctor
No.
CN-26
CN-81
DCL
DL1
DLCO
DLK
ECMA
ECMB
EG1
EG2
ESD
F1T
F2T
F3T
FD1
FD5
FD6
FFT
FLB
FLC
FLTP
FRB
FRC
FRT
FS1
FS2
FS4
FSB
FSOFSO+
GND
GND
GND
GND1
GND4
HEAT
IMPR
IMTP
JC01
JC02
JC03
JC04
JC11
JC12
JC13
Connecto No. of
r type
pins
DT
DT
HD10-6
24-21
24-31
DT
DT
DT
DT
24-23
DT-A
24-31
DT
DT
DT
DT
DT
DT
24-31
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
Terminal
DT
D375A-5
2
2
3
6
6
6
40
40
21
31
3
2
2
2
23
12
31
2
2
2
2
2
2
2
31
1
1
2
3
2
6
8
8
8
6
6
8

Place of use
Rotating lamp switch [cab]
Room lamp [cab]
Decelerator pedal potentiometer
Data link crossover connector
Engine controller
Engine controller
Intermediate connector (Engine side connector No. POW)
Intermediate connector (Engine side connector No. SIG)
Connector for option

1st clutch ECMV (fill switch)
2nd clutch ECMV (fill switch)
3rd clutch ECMV (fill switch)
F clutch ECMV (fill switch)
Left steering brake ECMV (fill switch)
Left steering clutch ECMV (fill switch)
Fuel temperature sensor
Right steering brake ECMV (fill switch)
Right steering clutch ECMV (fill switch)
F clutch ECMV (fill switch)
Fuse box 1
Fuse box 2
Fuse box 4
Fuel shut off valve
Fuel shut off valve
GND
GND (engine)
GND (engine)
GND
GND
Boost pressure sensor
Intake air temperature sensor
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Junction connector
Address
3-dimensional
drawing
F-9
E-8
R-1
K-3
N-1
K-4
E-7
d-6
Q-1
L-4
d-2
K-6
B-8
b-8
K-5
B-5
K-4
L-8
d-5
F-5
J-7
d-5
I-5
F-5
I-4
J-6
O-7
g-7
K-6
g-7
K-5
f-6
K-5
W-3
G-6
H-5
H-5
G-7
V-2
I-2
H-5
G-2
J-6
W-4
G-5
H-4
H-4
G-6
I-3
K-7
I-3
K-4
h-7
K-5
a-7
F-8
J-7
K-3
h-7
K-4
g-7
K-6
N-9
J-2
L-5
I-2
H-2
N-9
J-2
O-9
J-2
L-4
I-1
H-1
S-1
G-4
K-5
H-3
G-3
Y-5
B-9
Y-5
B-9
C-7
Y-3
C-9
Y-3
C-9
H-3
J-4
G-5
I-2
I-5
A-2
J-8
d-5
I-6
H-8
Z-6
H-8
Z-7
G-8
d-3
K-5
C-9
c-3
K-5
C-9
a-2
D-9
d-2
E-9
b-2
E-1
b-2
D-1
c-2
C-1
20-313

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

Address
3-dimensional
drawing
Left steering clutch ECMV (solenoid valve)
I-7
K-5
Solenoid valve for pitch
B-6
K-9
Solenoid valve for dual
C-7
K-9
Engine speed sensor (master)
d-6
K-4
E-8
Engine speed sensor (backup)
d-6
K-3
F-8
Work equipment small pump pressure sensor
E-8
K-8
Right steering brake ECMV (solenoid valve)
J-6
K-4
Right steering clutch ECMV (solenoid valve)
h-7
K-5
F clutch ECMV (solenoid valve)
g-6
K-7
Acceleration sensor
F-2
H-8
Sudden stop valve solenoid
I-7
K-3
GND
H-3
Timing rail actuator
a-8
K-8
Fuel control dial, full monolever unit
S-1
D-2
C-8
Blade tilt left oil pressure switch
Q-8
F-1
Transmission outlet speed sensor
J-7
K-8
K-6
W-5
E-2
A-9
D-1
V-7
E-2
J-2
A-7
E-1
V-8
A-4
g-7
J-7
Timing rail pressure sensor
d-4
I-8
Blade tilt right oil pressure sensor
Q-7
F-1
U-1
K-2
I-1
H-2
CAN terminal resistance
W-6
F-1
J-2
A-1
F-1
O-9
Place of use
20-315
TROUBLESHOOTING
CONNECTOR ARRANGEMENT DRAWING
20-316
1
D375A-5
TROUBLESHOOTING
D375A-5
20-317
TROUBLESHOOTING
20-318
1
D375A-5
TROUBLESHOOTING
D375A-5
20-319
TROUBLESHOOTING
20-320
1
D375A-5
TROUBLESHOOTING
D375A-5
20-321
TROUBLESHOOTING
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)
20-322
1
D375A-5
TROUBLESHOOTING
This circuit diagram has been made by extracting the monitor panel system, engine preheating, starting,
and charging system, light system, and communication network system from the overall electrical circuit
diagram.
D375A-5
20-323
TROUBLESHOOTING
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)
20-324
1
D375A-5
TROUBLESHOOTING
This circuit diagram has been made by extracting the engine controller system from the overall electrical
circuit diagram.
D375A-5
20-325
TROUBLESHOOTING
CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT)
20-326
1
D375A-5
TROUBLESHOOTING
This circuit diagram has been made by extracting the transmission controller system from the overall electrical circuit diagram.
D375A-5
20-327
TROUBLESHOOTING
CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT)
20-328
1
D375A-5
TROUBLESHOOTING
This circuit diagram has been made by extracting the steering controller system from the overall electrical
circuit diagram.
D375A-5
20-329
TROUBLESHOOTING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS

The terms male and female refer to the pins, while the terms male housing and female housing refer
to the mating portion of the housing.
X Type Connector
Number
of Pins
Male (Female housing)
Female (Male housing)
T-adapter
Part Number
Part number: 08055-00181
799-601-7010
799-601-7020
799-601-7030
799-601-7040
Terminal part number: 79A-222-3370

Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Wire size: 2.0
Quantity: 20 pieces
Grommet: red

Wire size: 2.0
Quantity: 20 pieces
Grommet: red
20-330
D375A-5
TROUBLESHOOTING
Number
of Pins
SWP Type Connector

799-601-7050
799-601-7060
12
799-601-7310
14
799-601-7070
D375A-5
T-adapter Part
Number
20-331
TROUBLESHOOTING
SWP Type Connector
Number
of Pins
16
T-adapter
Part Number
799-601-7320
Terminal part number:

Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Wire size: 0.85
Quantity: 20 pieces
Grommet: black

Wire size: 1.25
Quantity: 20 pieces
Grommet: red

Wire size: 1.25
Quantity: 20 pieces
Grommet: red
20-332
D375A-5
TROUBLESHOOTING
M Type Connector
Number
of Pins
T-adapter Part
Number
799-601-7080
799-601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340
D375A-5
20-333
(5)
1
TROUBLESHOOTING
Number
of Pins
S Type Connector
799-601-7140
10
(white)
799-601-7150
12
(white)
799-601-7350
16
(white)
799-601-7330
20-334
1
T-adapter Part
Number
D375A-5
TROUBLESHOOTING
Number
of Pins
S Type Connector
10
(blue)
12
(blue)
799-601-7160
16
(blue)
799-601-7170
D375A-5
T-adapter Part
Number
20-335
TROUBLESHOOTING
Number
of Pins
MIC Type Connector

T-adapter
Part Number
Body part number: 79A-222-2640

(Quantity: 5 pieces)

11


799-601-2710


799-601-2950


13
799-601-2720

20-336

D375A-5
TROUBLESHOOTING
Number
of Pins
MIC Type Connector

17
799-601-2730


21
D375A-5
T-adapter Part
Number
799-601-2740




20-337
TROUBLESHOOTING
Number
of Pins
AMP040 Type Connector

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

12
799-601-7190

16
799-601-7210

20
799-601-7220

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

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

10
T-adapter
Part Number
799-601-3460
20-340
T-adapter
Part Number
Number
of Pins
T-adapter
Part Number
D375A-5
TROUBLESHOOTING
Number
of Pins
KES1 Automobile Type Connector

Part number: 08027-10210 (Natural color)

08027-10220 (Black)

08027-10270 (Black)

08027-10420 (Black)

08027-10470 (Black)

08027-10620 (Black)
D375A-5
T-adapter Part
Number

08027-10670 (Black)
20-341
TROUBLESHOOTING
Number
of Pins
KES1 Automobile Type Connector


08027-10820 (Black)
20-342
T-adapter
Part Number

08027-10870 (Black)
D375A-5
TROUBLESHOOTING
Number
of Pins
F Type Connector
Number
of Pins
Connector for relay (Socket)

T-adapter
Part Number
799-601-7360
799-601-7370
D375A-5
T-adapter
Part Number
20-343
(6)
1
TROUBLESHOOTING
[The pin No. is also marked on the connector (electric wire insertion end)]
Type
(shell
size
code)
HD30 Series connector

Body (plug)
Body (receptacle)
Pin (male terminal)
Pin (female terminal)
T-adapter
Part Number
799-601-9210
18-8
(1)
Part number: 08191-11201, 08191-11202

08191-11205, 08191-11206
Part number: 08191-14101, 08191-14102

08191-14105, 08191-14106
Pin (male terminal)
799-601-9210
Part number: 08191-11201, 08191-12202

08191-11205, 08191-12206
Pin (male terminal)
Part number: 08191-13101, 08191-13102

08191-13105, 08191-13106
799-601-9220
18-14
(2)
Part number: 08191-21201, 08191-12202

08191-21205, 08191-12206
Part number: 08191-24101, 08191-24102

08191-24105, 08191-24106
Pin (male terminal)
799-601-9220
Part number: 08191-22201, 08191-22202

08191-22205, 08191-22206
20-344
1
Part number: 08191-23101, 08191-23102

08191-23105, 08191-23106
D375A-5
TROUBLESHOOTING
Type
(shell
size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter Part
Number
799-601-9230
18-20
(3)
Part number: 08191-31201, 08191-31202

Part number: 08191-34101, 08191-34102

Pin (male terminal)
799-601-9230
Part number: 08191-32201, 08191-32202

Pin (male terminal)
Part number: 08191-33101, 08191-33102

799-601-9240
18-21
(4)
Part number: 08191-41201, 08191-42202

Part number: 08191-44101, 08191-44102

Pin (male terminal)
799-601-9240
Part number: 08191-42201, 08191-42202
D375A-5
Part number: 08191-43101, 08191-43102
20-345
1
TROUBLESHOOTING
Type
(shell
size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter
Part Number
799-601-9250
24-9
(5)
Part number: 08191-51201, 08191-51202

Part number: 08191-54101, 08191-54102

Pin (male terminal)
799-601-9250
Part number: 08191-52201, 08191-52202

Pin (male terminal)
Part number: 08191-53101, 08191-53102

799-601-9260
24-23
(6)
Part number: 08191-61201, 08191-62202

08191-61205, 08191-62206
Part number: 08191-64101, 08191-64102

08191-64105, 08191-64106
Pin (male terminal)
799-601-9260
Part number: 08191-62201, 08191-62202

08191-62205, 08191-62206
20-346
1
(6)
Part number: 08191-63101, 08191-63102

08191-63105, 08191-63106
D375A-5
TROUBLESHOOTING
Type
(shell
size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter Part
Number
799-601-9270
24-21
(7)
Part number: 08191-71201, 08191-71202

08191-71205, 08191-71206
Part number: 08191-74101, 08191-74102

08191-74105, 08191-74106
Pin (male terminal)
799-601-9270
Part number: 08191-72201, 08191-72202

08191-72205, 08191-72206
Part number: 08191-73102, 08191-73102

08191-73105, 08191-73106
Pin (male terminal)
799-601-9280
24-22
(8)
Part number: 08191-81201, 08191-81202,

08191-81203, 08191-81204,
08191-81205, 08191-80206
Part number: 08191-84101, 08191-84102,

08191-84103, 18191-84104,
08191-84105, 08191-84106
Pin (male terminal)
799-601-9280
Part number: 08191-82201, 08191-82202,

08191-82203, 08191-82204,
08191-82205, 08191-82206
D375A-5
Part number: 08191-83101, 08191-83102,

08191-83103, 18191-83104,
08191-83105, 08191-83106
20-347
TROUBLESHOOTING
Type
(shell
size
code)

Body (plug)
Body (receptacle)
Pin (male terminal)
T-adapter
Part Number
799-601-9290
24-31
(9)
Part number: 08191-91203, 08191-91204

08191-91205, 08191-91206
Part number: 08191-94103, 08191-94104

08191-94105, 08191-94106
Pin (male terminal)
799-601-9290
Part number: 08191-92203, 08191-92204

08191-92205, 08191-92206
20-348
Part number: 08191-93103, 08191-93104

08191-93105, 08191-93106
D375A-5
TROUBLESHOOTING
Number
of Pins
DT Series connector
Body (plug)
Body (receptacle)
799-601-9020
Part number: 08192-12200 (normal type)

08192-22200 (fine wire type)

799-601-9030


799-601-9040


799-601-9050

D375A-5
T-adapter Part
Number

20-349
1
TROUBLESHOOTING
Number
of Pins
DT Series connector
Body (plug)
Body (receptacle)
8GR:799-601-9060
8B :799-601-9070
8G :799-601-9080
8BR :799-601-9080
Part number: 08192-1820 ! (normal type)

08192-2820 ! (fine wire type)

12GR:799-601-9110
12B :799-601-9120
12G :799-601-9130
12BR :799-601-9140
12

20-350
(5)
1
T-adapter Part
Number

D375A-5
TROUBLESHOOTING
Number
of Pins
DTM Series connector

Body (plug)
Body (receptacle)
799-601-9010
Number
of Pins
DTHD Series connector

Body (plug)
Body (receptacle)
T-adapter Part
Number
Part number: 08192-31200 (Contact size #12)

08192-41200 (Contact size #8)
08192-51200 (Contact size #4)
D375A-5
T-adapter Part
Number
Part number: 08192-31100 (Contact size #12)

08192-41100 (Contact size #8)
08192-51100 (Contact size #4)
20-351
1
TROUBLESHOOTING
No. of
pins
DRC26 Series connector

Body (plug)
Body (receptacle)
24
799-601-9360
Part No.: 7821-93-3110
40
(A)
799-601-9350
Part No.: 7821-93-3120
40
(B)
799-601-9350
20-352
(7)
1
T-adapter
Part No.
Part No.: 7821-93-3130
D375A-5
TROUBLESHOOTING
T-BRANCH BOX AND T-BRANCH TABLE
D375A-5
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
Measurement box
Measurement box
Measurement box
Measurement box
Plate
Plate
Plate
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
BENDIX (MS)
Case
MIC
MIC
MIC
MIC
MIC
ECONO
ECONO
ECONO
ECONO
ECONO
DLI
DLI
DLI
Additional cable
Case
X
X
X
X
SWP
SWP
SWP
SWP
SWP
M
M
M
M
M
M
S
S
799-601-2900
799-601-2600
799-601-3100
799-601-3200
799-601-3300
799-601-3360
799-601-3370
799-601-3380
799-601-3410
799-601-3420
799-601-3430
799-601-3440
799-601-3450
799-601-3460
799-601-3510
799-601-3520
799-601-3530
799-601-2910
799-601-3470
799-601-2710
799-601-2720
799-601-2730
799-601-2740
799-601-2950
799-601-2750
799-601-2760
799-601-2770
799-601-2780
799-601-2790
799-601-2810
799-601-2820
799-601-2830
799-601-2840
799-601-2850
799-601-7010
799-601-7020
799-601-7030
799-601-7040
799-601-7050
799-601-7060
799-601-7310
799-601-7070
799-601-7320
799-601-7080
799-601-7090
799-601-7110
799-601-7120
799-601-7130
799-601-7340
799-601-7140
799-601-7150
No. of pins
799-601-2800
Connector type or
part name
799-601-2700
Part No.
799-601-2500
The vertical column shows part number of T-Branch Box or T-Branch, and horizontal column shows part
number of Harness Checker Assy.
Econo-21P
MS-37P
MS-37P
Econo-24P
For MS box
For MS box
For MS box
24P
24P
17P
17P
5P
10P
5P
14P
19P
14P
5P
13P
17P
21P
9P
2P
3P
4P
8P
12P
8P
12P
16P
1P
2P
3P
4P
6P
8P
12P
14P
16P
1P
2P
3P
4P
6P
8P
8P
10P-White
20-353
(7)
1
20-354
(7)
1
799-601-9300
799-601-9200
799-601-9100
799-601-9000
799-601-8000
799-601-7500
799-601-7400
799-601-7100
799-601-7000
799-601-6500
799-601-6000
799-601-5500
799-601-3000
S
S
S
S
AMP040
AMP040
AMP040
AMP040
Short connector
Case
Case
070
070
070
070
070
Relay connector
Relay connector
JFC connector
DTM
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
DT
HD30
HD30
HD30
HD30
HD30
HD30
HD30
HD30
HD30
Plate
Measurement box
Case
Case
DRC26
DRC26
For NE, G sensor
For fuel, boost press.
PVC socket
799-601-2900
799-601-7160
799-601-7170
799-601-7330
799-601-7350
799-601-7180
799-601-7190
799-601-7210
799-601-7220
799-601-7230
799-601-7240
799-601-7270
799-601-7510
799-601-7520
799-601-7530
799-601-7540
799-601-7550
799-601-7360
799-601-7370
799-601-7380
799-601-9010
799-601-9020
799-601-9030
799-601-9040
799-601-9050
799-601-9060
799-601-9070
799-601-9080
799-601-9090
799-601-9110
799-601-9120
799-601-9130
799-601-9140
799-601-9210
799-601-9220
799-601-9230
799-601-9240
799-601-9250
799-601-9260
799-601-9270
799-601-9280
799-601-9290
799-601-9310
799-601-9320
799-601-9330
799-601-9340
799-601-9350
799-601-9360
799-601-9410
799-601-9420
799-601-9430
No. of pins
799-601-2800
Connector type or
part name
799-601-2700
Part No.
799-601-2500
TROUBLESHOOTING
12P-Blue
16P-Blue
16P-White
12P-White
8P
12P
16P
20P
X-2
10P
12P
14P
18P
20P
5P
6P
2P
2P
2P
3P
4P
6P
8P-Gray
8P-Black
8P-Green
8P-Brown
12P-Gray
12P-Black
12P-Green
12P-Brown
18-8
18-14
18-20
18-21
24-9
24-16
24-21
24-23
24-31
For HD30
For DT, HD
40P
24P
2P
3P
2P
D375A-5
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING WHEN
SERVICE CODE IS DISPLAYED
(SERVICE CODE)
Information in troubleshooting table ........................................................................................................

Service code E0101 [Abnormality in network system (steering)] ..........................................................
Service code E0104 [Abnormality in network system (monitor panel)] .................................................
Service code E0111 (Abnormality in steering controller power supply system) .....................................
Service code E0112 (Abnormality in transmission controller power supply system) .............................
Service code E0120 (Short circuit in caution lamp system) ..................................................................
Service code E0121 (Short circuit in caution buzzer system) ...............................................................
Service code E0142 (Abnormality in transmission controller 5 V power supply system) ......................
Service code E0143 (Abnormality in steering controller 5 V power supply system) ..............................
Service code E0145 (Abnormality in steering controller 24 V power supply system) ............................
Service code E0146 (Abnormality in transmission controller 24 V power supply system) ....................
Service code E0151 (Abnormality in selection of steering controller specification) ...............................
Service code E0160 (Abnormality in transmission controller ROM) ......................................................
Service code E0161 (Abnormality in steering controller ROM) .............................................................
Service code E0164 [Abnormality in network system (transmission)] ...................................................
Service code E0176 (Disconnection in battery relay system) ...............................................................
Service code E0177 (Short circuit in battery relay system) ...................................................................
Service code E0178 (Disconnection in neutral safety relay system) .....................................................
Service code E0179 (Short circuit in neutral safety relay system) ........................................................
Service code E0211 (Abnormal torque converter oil temperature) ........................................................
Service code E0212 (Short circuit in torque converter lock-up solenoid system) ..................................
Service code E0213 (Disconnection in torque converter lock-up solenoid system) ..............................
Service code E0221 (Disconnection or short circuit in pitch angle sensor system) ..............................
Service code E0225 (Slip of power train clutch) ....................................................................................
Service code E0230 [Abnormality in both forward-reverse potentiometer systems (1)] ........................
Service code E0233 (Disconnection or short circuit in forward-reverse potentiometer 1 system) ........
Service code E0234 (Disconnection or short circuit in forward-reverse potentiometer 2 system) ........
Service code E0235 (Deviation of forward-reverse potentiometer system signals) ..............................
Service code E0236 (Disconnection or short circuit in shift-up switch systems) ...................................
Service code E0237 (Disconnection or short circuit in shift-down switch systems) ...............................
Service code E0238 (Disconnection or short circuit in parking brake lever switch systems) ................
Service code E0239 (Disagreement of parking brake lever switch system signals) .............................
Service code E0250 (Disconnection in transmission forward clutch ECMV system) ............................
Service code E0251 (Short circuit in transmission forward clutch ECMV system) ................................
Service code E0252 (Disconnection in transmission reverse clutch ECMV system) ............................
Service code E0253 (Short circuit in transmission reverse clutch ECMV system) ................................
Service code E0254 (Disconnection in transmission 1st clutch ECMV system) ...................................
Service code E0255 (Short circuit in transmission 1st clutch ECMV system) .......................................
Service code E0256 (Disconnection in transmission 2nd clutch ECMV system) ..................................
Service code E0257 (Short circuit in transmission 2nd clutch ECMV system) ......................................
Service code E0258 (Disconnection in transmission 3rd clutch ECMV system) ...................................
Service code E0259 (Short circuit in transmission 3rd clutch ECMV system) .......................................
Service code E0260 (Defective engagement of transmission forward clutch) ......................................
Service code E0261 (Defective disengagement of transmission forward clutch) ..................................
Service code E0262 (Defective engagement of transmission reverse clutch) ......................................
Service code E0263 (Defective disengagement of transmission reverse clutch) ..................................
Service code E0264 (Defective engagement of transmission 1st clutch) ..............................................
D375A-5
20-404
20-406
20-408
20-410
20- 411
20-413
20-415
20-416
20-417
20-419
20-421
20-422
20-423
20-424
20-425
20-425
20-426
20-428
20-429
20-430
20-432
20-434
20-435
20-436
20-437
20-439
20-439
20-440
20-440
20-441
20-443
20-444
20-445
20-447
20-449
20-451
20-452
20-453
20-454
20-455
20-456
20-457
20-458
20-459
20-460
20-461
20-462
20-463
20-464
20-465
20-466
20-401
(7)
1
TROUBLESHOOTING
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
20-402
(7)
1
E0265
E0266
E0267
E0268
E0269
E0270
E0271
E0306
E0307
E0308
E0309
E0310
E0311
E0312
E0321
E0322
E0323
E0324
E0329
E0364
E0365
E0366
E0367
E0405
E0430
E0431
E0432
E0486
E0501
E0610
E0611
E0660
E0661
E0721
E0730
E0731
E0732
E0733
E0734
E0735
E0736
E0750
E0751
E0752
E0753
E0754
E0755
E0756
E0757
E0760
E0761
E0762
E0763
E0764
E0765
E0766
E0767
E0779
E0780
E0781
(Defective disengagement of transmission 1st clutch) .......................................... 20-467

(Defective engagement of transmission 2nd clutch) ............................................. 20-468
(Defective disengagement of transmission 2nd clutch) ........................................ 20-469
(Defective engagement of transmission 3rd clutch) .............................................. 20-470
(Defective disengagement of transmission 3rd clutch) ......................................... 20-471
[Double trouble in transmission clutch (Defective engagement)] .......................... 20-472
[Double trouble in transmission clutch (Defective disengagement)] ..................... 20-472
(Short circuit in blade tilt right oil pressure switch system) ................................... 20-473
(Short circuit in blade tilt left oil pressure switch system) ...................................... 20-474
(Short circuit in ripper lift raise oil pressure switch system) .................................. 20-475
(Short circuit in ripper lift lower oil pressure switch system) ................................. 20-476
(Short circuit in ripper tilt-in oil pressure switch system) ....................................... 20-477
(Disconnection or short circuit in blade pitch switch systems) .............................. 20-478
(Disconnection or short circuit in blade tilt switch systems) .................................. 20-480
(Disconnection in blade dual selector solenoid system) ....................................... 20-482
(Short circuit in blade dual selector solenoid system) ........................................... 20-483
(Disconnection in blade pitch selector solenoid system) ...................................... 20-484
(Short circuit in blade pitch selector solenoid system) .......................................... 20-485
(Abnormal hydraulic oil temperature) ................................................................. 20-485-1
(Disconnection in front large pump oil pressure sensor system) .......................... 20-486
(Short circuit in front large pump oil pressure sensor system) .............................. 20-487
(Disconnection in center small pump oil pressure sensor system) ....................... 20-488
(Short circuit in center small pump oil pressure sensor system) ........................... 20-489
(Disconnection or short circuit in fuel control dial system) .................................... 20-490
(Engine oil: Abnormal oil pressure) ................................................................... 20-491-1
(Abnormal radiator coolant level) ...................................................................... 20-491-1
(Radiator coolant: Overheating).......................................................................... 20-491-1
(Abnormality in selection of transmission controller specification) ........................ 20-492
(Disconnection or short circuit in acceleration sensor system) ............................. 20-493
(Disconnection in back-up alarm relay system) .................................................... 20-494
(Short circuit in back-up alarm relay system) ........................................................ 20-496
(Disconnection in ACC signal drive relay system) ................................................ 20-498
(Short circuit in ACC signal drive relay system) .................................................... 20-499
(Disconnection or short circuit in pitch angle sensor system) ............................... 20-500
[Abnormality in both steering potentiometer systems (1)] ..................................... 20-502
(Disconnection or short circuit in steering potentiometer 1 system) ..................... 20-504
(Disconnection or short circuit in steering potentiometer 2 system) ..................... 20-506
(Deviation of steering potentiometer system signals) ........................................... 20-507
(Disconnection or short circuit in brake potentiometer system) ............................ 20-508
(Disconnection in right steering clutch ECMV system) ......................................... 20-510
(Short circuit in right steering clutch ECMV system) ............................................. 20- 511
(Disconnection in left steering clutch ECMV system) ........................................... 20-512
(Short circuit in left steering clutch ECMV system) ............................................... 20-513
(Disconnection in right steering brake ECMV system) .......................................... 20-514
(Short circuit in right steering brake ECMV system) ............................................. 20-515
(Disconnection in left steering brake ECMV system) ............................................ 20-516
(Short circuit in left steering brake ECMV system) ............................................... 20-517
(Defective engagement of right steering clutch) ................................................... 20-518
(Defective disengagement of right steering clutch) ............................................... 20-519
(Defective engagement of left steering clutch) ...................................................... 20-520
(Defective disengagement of left steering clutch) ................................................. 20-521
(Defective engagement of right steering brake) .................................................... 20-522
(Defective disengagement of right steering brake) ............................................... 20-523
(Defective engagement of left steering brake) ...................................................... 20-524
(Defective disengagement of left steering brake) ................................................. 20-525
(Disconnection in sudden stop prevention solenoid system) ................................ 20-526
(Short circuit in sudden stop prevention solenoid system) .................................... 20-527
(Disconnection or short circuit in parking brake lever switch systems) ................. 20-528
D375A-5
TROUBLESHOOTING
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
Service code
D375A-5
E0782
E0930
E0931
E0932
E0933
E1939
EC111
EC112
EC113
EC115
EC116
EC117
EC118
EC119
EC121
EC122
EC123
EC131
EC132
EC133
EC134
EC135
EC141
EC143
EC144
EC145
EC151
EC153
EC154
EC221
EC222
EC234
EC254
EC259
EC261
EC263
EC265
EC316
EC318
EC346
EC384
EC423
EC441
EC442
EC451
EC452
EC455
EC467
EC468
EC514
EC554
(Disagreement of parking brake lever switch system signals) .............................

(Disconnection in engine speed sensor system) ..................................................
(Disconnection in engine speed sensor system) ..................................................
(Disconnection in transmission speed sensor system) ........................................
(Disconnection in transmission speed sensor system) ........................................
(Abnormality in J1939 communication system) ....................................................
(Abnormality in engine controller memory) ...........................................................
(Abnormality in timing rail actuator) ......................................................................
(Abnormal current in timing rail actuator system) .................................................
(Abnormality in engine speed sensor 2 systems) .................................................
(Abnormally high level in timing rail pressure sensor system) ..............................
(Abnormally low level in timing rail pressure sensor system) ...............................
(Abnormally high level in fuel pump pressure sensor system) .............................
(Abnormally low level in fuel pump pressure sensor system) ...............................
(Abnormality in engine speed sensor 1 systems) .................................................
(Abnormally high level in boost pressure sensor system) ....................................
(Abnormally low level in boost pressure sensor system) .....................................
(Abnormally high level in throttle sensor system) .................................................
(Abnormally low level in throttle sensor system) ..................................................
(Abnormally high level in remote throttle sensor system) .....................................
(Abnormally low level in remote throttle sensor system) ......................................
(Abnormally high level in engine oil pressure sensor system) .............................
(Abnormally low level in engine oil pressure sensor system) ...............................
(Lowering of engine oil pressure) .........................................................................
(Abnormally high level in engine coolant temperature sensor system) ................
(Abnormally low level in engine coolant temperature sensor system) .................
(Rise of engine coolant temperature) ...................................................................
(Abnormally high level in air intake temperature sensor system) .........................
(Abnormally low level in air intake temperature sensor system) ..........................
(Abnormally high level in atmospheric pressure sensor system) .........................
(Abnormally low level in atmospheric pressure sensor system) ...........................
(Over-speed) ........................................................................................................
(Abnormal voltage of fuel shut-off valve) ..............................................................
(Abnormality in fuel shut-off valve) .......................................................................
(Abnormal rise of fuel temperature) ......................................................................
(Abnormally high level in fuel temperature sensor system) ..................................
(Abnormally low level in fuel temperature sensor system) ...................................
(Abnormal current of fuel pump actuator) .............................................................
(Abnormality in fuel pump actuator) .....................................................................
(Abnormality in power-down unit of engine controller) .........................................
(Abnormality in preheater control system) ............................................................
(Abnormality in in-range of timing rail pressure sensor system) ..........................
(Abnormally low level in battery voltage system) .................................................
(Abnormally high level in battery voltage system) ................................................
(Abnormally high level in fuel rail pressure sensor system) .................................
(Abnormally low level in fuel rail pressure sensor system) ...................................
(Abnormal current of fuel rail actuator) .................................................................
(Abnormality in timing rail actuator control) ..........................................................
(Abnormality in fuel rail actuator control) ..............................................................
(Abnormality in fuel rail actuator) ..........................................................................
(Abnormality in in-range of fuel rail pressure sensor system) ..............................
20-530
20-531
20-533
20-535
20-537
20-539
20-540
20-540
20-541
20-542
20-544
20-545
20-546
20-547
20-547
20-548
20-549
20-550
20-551
20-552
20-553
20-554
20-555
20-555
20-556
20-557
20-557
20-558
20-559
20-560
20-561
20-561
20-562
20-563
20-563
20-564
20-565
20-566
20-567
20-568
20-570
20-572
20-574
20-574
20-575
20-576
20-577
20-578
20-578
20-579
20-580
20-403
1
(6)
TROUBLESHOOTING
INFORMATION IN TROUBLESHOOTING TABLE

The following information is summarized in the troubleshooting table and the related electrical circuit diagram. Before carrying out troubleshooting, understand that information fully.
User code
Service code
Display on panel Display on panel
Trouble
Trouble in machine
Contents of trouble Contents of trouble detected by monitor panel or controller
Action of controller Action taken by controller to protect system or devices when monitor panel or controller detects trouble
Problem that
Problem that appears on machine as result of action taken by monitor panel or controller (shown above)
appears on machine
Related information Information related to detected trouble or troubleshooting
Cause
2
Possible causes
and standard value in normal state
20-404
1
Standard value in normal state/Remarks on troubleshooting

<Contents of description>
Standard value in normal state to judge possible causes
Remarks on judgment
<Troubles in harness>
Disconnection
Connector is connected imperfectly or harness is broken.
Short circuit with chassis ground
Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit.
Short circuit with power source
Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
Short circuit
Independent harnesses are in contact with each other abnormally.
Possible causes of trouble

(Given numbers are reference numbers, which do not <Precautions for troubleshooting>
indicate priority)
1Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
3
If connector No. has no marks of male and female, disconnect
connector and insert T-adapters in both male side and female
side.
If connector No. has marks of male and female, disconnect
connector and connect T-adapter to only male side or female side.
2Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as explained below for troubleshooting, unless otherwise specified.
Connect positive (+) lead to pin No. or harness entered on front
4
side.
Connect negative () lead to pin No. or harness entered on rear
side.
D375A-5
TROUBLESHOOTING
Part of electric circuit diagram related to trouble

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

User code
Service code
CALL03
E0101
Trouble
Abnormality in network system (steering)

(Monitor panel system)
Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of steering controller.
Action of controller
Flashes caution lamp and turns on caution buzzer.

Limits operation of engine and transmission.
Monitor panel may not display normally.
Problem that
Once machine is stopped, engine speed is limited to medium (half).
appears on machine
Once machine is stopped, travel is limited to F1 and R1.
Related information
Connection state (ONOFF) of S-NET can be checked in monitoring mode.

(Code 5N: Connection state of S-NET communication)
Method of reproducing service code: Turn starting switch ON.
Cause
Prepare with starting switch OFF, then carry out troubleshooting

Disconnection in wiring harwithout turning starting switch ON.
ness
Wiring harness between S03 (female) 9
1 (Disconnection in wiring or
Resistance Max. 1
NGICN2 (female) K
defective contact in connecWiring harness between S03 (female) 8
tor)
Resistance Max. 1
NGICN2 (female) U
Possible causes

without turning starting switch ON.
Short circuit with chassis
2 ground in wiring harness
Short circuit of wiring harness between S03
(Contact with ground circuit) (female) 9 S01 (female) 8 or NGICN2 (fe- Resistance Min. 1 M
male) K with chassis ground
Short circuit with power
3 source in wiring harness
(Contact with 24 V circuit)
Defective monitor panel

(tachometer module)
5 Defective steering controller
20-406
1
Prepare with starting switch OFF, then turn starting switch ON and
carry out troubleshooting.
(female) 9 S01 (female) 8 or NGICN2 (female) K with chassis ground
Voltage
Max. 1 V
S03
Voltage
Between 9 8
69V
NGICN2
Voltage
Between K U
69V
D375A-5
TROUBLESHOOTING
Circuit diagram related to S-NET communication
D375A-5
20-407
1
TROUBLESHOOTING SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)]
SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)]

User code
Service code
CALL03
E0104
Trouble
Abnormality in network system (monitor panel)

Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of monitor panel (caution module).

Problem that
appears on machine
Related information

Cause
Disconnection in wiring har- Prepare with starting switch OFF, then carry out troubleshooting
ness
defective contact in connec- Wiring harness between S03 (female) @
Resistance Max. 1
CN1 (female) A
tor)
(Contact with ground circuit) (female) @ CN1 (female) A with chassis
Resistance Min. 1 M
ground
Possible causes
and standard valShort circuit with power
ue in normal state 3 source in wiring harness

4
(tachometer module)
20-408
1

(caution module)
(female) @ CN1 (female) A with chassis
ground
Voltage
Max. 1 V
S03
Voltage
Between @ 8
69V
CN1
Voltage
Between A @
69V
D375A-5
TROUBLESHOOTING SERVICE CODE E0104 [ABNORMALITY IN NETWORK SYSTEM (MONITOR PANEL)]
D375A-5
20-409
1
TROUBLESHOOTING

User code
Service code
CALL03
E0105
Trouble

Contents of trouble Monitor panel (Tachometer module) cannot recognize S-NET of steering controller.

Problem that
appears on machine
Related information
Possible causes
20-410
1

Cause

Carry out troubleshooting for service code [E0101].
D375A-5
SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER

SUPPLY SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY

SYSTEM)
User code
Service code
CALL
E0111
Trouble
Abnormality in steering controller power supply system

(Steering controller system)
Contents of trouble Source voltage of steering controller is below 17 V.

Limits operation of engine, transmission, and brake.
Relays and solenoids may not be driven and system may not operate normally as result.
Problem that
appears on machine Once machine is stopped, engine speed is limited to medium (half).
Once machine is stopped, it cannot travel any more.
Related information
Charge level (Voltage) of battery can be checked in monitoring mode.

(Code dA: Battery voltage)
Cause
Possible causes
Defective circuit breaker

1
(CB1)
If circuit breaker is turned OFF, circuit probably has short circuit with
chassis ground.
2 Defective fusible link (96A)
If fusible link is broken, circuit probably has short circuit with chassis
ground.
Disconnection in wiring harness

defective contact in connector)

Wiring harness between NGICN3 (female) 1,
Resistance Max. 1
A CB1 (1)
Wiring harness between CB1 (2) fusible link
Resistance Max. 1
battery relay terminal M
Wiring harness between NGICN3 (female) K,
Resistance Max. 1
U, V, W chassis ground
Short circuit of wiring harness between

NGICN3 (female) 1, A CB1 (1) with chas- Resistance Min. 1 M
sis ground
(Contact with ground circuit)
Short circuit of wiring harness between CB1
(2) fusible link battery relay terminal M with Resistance Min. 1 M
chassis ground
D375A-5
NGICN3
Voltage
Between 1, A K, U, V, W
20 30 V
20-411
1
TROUBLESHOOTING
SERVICE CODE E0111 (ABNORMALITY IN STEERING CONTROLLER POWER

SUPPLY SYSTEM)
Circuit diagram related to steering controller power supply
20-412
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0112 (ABNORMALITY IN TRANSMISSION CONTROLLER POWER

SUPPLY SYSTEM)

SUPPLY SYSTEM)
User code
Service code
CALL
E0112
Trouble
Abnormality in transmission controller power supply system

(Transmission controller system)
Contents of trouble Source voltage of transmission controller is below 17 V.

Relays and solenoids may not be driven and system may not operate normally as result.
Problem that
Related information
Charge level (Voltage) of battery can be checked in monitoring mode.

Cause
Possible causes

1
(CB3)
chassis ground.
2 Defective fusible link (96A)
ground.


Wiring harness between TMCN3 (female) 1,
Resistance Max. 1
A CB3 (1)
Wiring harness between CB3 (2) fusible link
Resistance Max. 1
battery relay terminal M
Wiring harness between TMCN3 (female) K,
Resistance Max. 1
U, V, W chassis ground

TMCN3 (female) 1, A CB3 (1) with chassis Resistance Min. 1 M
ground
Short circuit of wiring harness between CB3
(2) fusible link battery relay terminal M with Resistance Min. 1 M
chassis ground
Defective transmission con5
troller
TMCN3
Voltage
Between 1, A K, U, V, W
D375A-5
20 30 V
20-413
1
TROUBLESHOOTING

SUPPLY SYSTEM)
Circuit diagram related to transmission controller power supply
20-414
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0120 (SHORT CIRCUIT IN CAUTION LAMP SYSTEM)
SERVICE CODE E0120 (SHORT CIRCUIT IN CAUTION LAMP SYSTEM)

User code
Service code
CALL03
E0120
Trouble
Short circuit in caution lamp system

Contents of trouble Abnormal current flowed when caution lamp circuit output GND signal.
Turns on caution buzzer.

Action of controller Stops caution lamp circuit from outputting GND signal.
Caution lamp does not light up or flash.
Problem that
appears on machine
Related information
Method of reproducing service code:

Turn starting switch ON. (Lamp lights up for 2 seconds when switch is turned ON.)
Cause
Defective caution lamp

(Internal short circuit)
Possible causes
and standard val- 2 source in wiring harness
ue in normal state

375 (male)
Resistance
Between 1 2
100 400
Short circuit of wiring harness between 375
(female) 2 CN2 (female) 7 with power
source
Voltage
Max. 1 V
3 Defective monitor panel
CN2
Caution lamp
Voltage
Between 7 chassis
ground
When turned OFF
20 30 V
When turned ON
Max. 6 V
Circuit diagram related to caution lamp
D375A-5
20-415
1
TROUBLESHOOTING
SERVICE CODE E0121 (SHORT CIRCUIT IN CAUTION BUZZER SYSTEM)
SERVICE CODE E0121 (SHORT CIRCUIT IN CAUTION BUZZER SYSTEM)

User code
Service code
CALL03
E0121
Trouble
Short circuit in caution buzzer system

Contents of trouble Abnormal current flowed when caution buzzer circuit outputted GND signal.
Turns on caution lamp.

Action of controller Stops caution buzzer circuit from outputting GND signal.
Caution buzzer does not sound.
Problem that
appears on machine
Related information

Turn starting switch ON. (Buzzer sounds for 1 second when switch is turned ON.)
Cause
Possible causes
Defective caution buzzer



217 (male)
Resistance
Between 1 2
200
Short circuit of wiring harness between 217
(female) 1 CN2 (female) 8 with power
source
Voltage
Max. 1 V
CN2
Between 8 chassis
ground
Caution buzzer
Voltage
When turned OFF
20 30 V
When turned ON
(sounded)
Max. 3 V
Circuit diagram related to caution buzzer
20-416
1
D375A-5
SERVICE CODE E0142 (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V

POWER SUPPLY SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0142 (ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER

SUPPLY SYSTEM)
User code
Service code
CALL03
E0142
Contents of trouble
Trouble
Abnormality in transmission controller 5 V power supply system

Voltage of 5 V power supply circuit for sensors of transmission controller is below 4.5 V or above 5.5 V.
Abnormal current flowed in 5 V power supply circuit for sensors of transmission controller.

Action of controller Stops 5 V power supply circuit from outputting if abnormal current flows.
System may not operate normally.
Problem that
appears on machine
Related information Method of reproducing service code: Turn starting switch ON.
Cause

TL1 (male)
Defective forward-reverse
1 potentiometer
Between L J
Sensor 1 (FR3)
Between L chassis
ground
Between O Q
Sensor 2 (FR4)
Between O chassis
ground
Resistance
2 k 20%
Min. 1 M
2 k 20%
Min. 1 M

Possible causes
and standard val2
ground
in
wiring
harness
ue in normal state
(Contact with ground circuit) TMCN1 (female) L TL1 (female) L or TL1 Resistance Min. 1 M
(female) O with chassis ground
TMCN1 (female) L TL1 (female) L or TL1
(female) O with chassis ground
Voltage
Max. 1 V
troller
TMCN1
Voltage
Between L K
D375A-5
4.5 5.5 V
20-417
1
TROUBLESHOOTING

Circuit diagram related to transmission controller 5 V power supply
20-418
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0143 (ABNORMALITY IN STEERING CONTROLLER 5 V POWER

SUPPLY SYSTEM)

SUPPLY SYSTEM)
User code
Service code
CALL03
E0143
Contents of trouble
Trouble
Abnormality in steering controller 5 V power supply system

Voltage of 5 V power supply circuit for sensors of steering controller is below 4.5 V or above 5.5 V.
Abnormal current flowed in 5 V power supply circuit for sensors of steering controller.

Problem that
appears on machine
Cause
Defective fuel control dial

When connector shown at right is disconnected, if service

code changes to P (to indicate that trouble is repaired), Fuel control
dial
trouble is in system.
Disconnect connector with starting switch OFF, then
connector
turn starting switch ON and carry out troubleshooting.

Defective brake potentiome- code changes to P (to indicate that trouble is repaired),
BRK
2 ter
connector
Defective acceleration sen- code changes to P (to indicate that trouble is repaired),
SS3
3 sor
connector
TL1 (male)
Possible causes
Defective steering potenti4 ometer

Between A G
Sensor 1 (ST1)
Between A chassis
ground
Between M F
Sensor 2 (ST2)
Between M chassis
ground
Resistance
2 k 20%
Min. 1 M
2 k 20%
Min. 1 M


NGICN1 (female) L TL1 (female) A, TL1
(Contact with ground circuit) (female) M, fuel control dial connector (feResistance Min. 1 M
male) 1, BRK (female) C, or SS3 (female) 8
with chassis ground

D375A-5
NGICN1 (female) L TL1 (female) A, TL1
(female) M, fuel control dial connector (female) 1, BRK (female) C, or SS3 (female) 8
with chassis ground
Voltage
Max. 1 V
NGICN1
Voltage
Between L K
4.5 5.5 V
20-419
1
TROUBLESHOOTING

SUPPLY SYSTEM)
20-420
1
D375A-5
TROUBLESHOOTING

SUPPLY SYSTEM)

SUPPLY SYSTEM)
User code
Service code
CALL03
E0145
Contents of trouble
Trouble
Abnormality in steering controller 24 V power supply system

Voltage of 24 V power supply circuit for sensors of steering controller is below 17 V or above 30 V.
Abnormal current flowed in 24 V power supply circuit for sensors of steering controller.

Problem that
appears on machine
Cause
Defective machine inclina1 tion angle sensor

code changes to P (to indicate that trouble is repaired),
PAS
connector

Possible causes
Short
circuit
with
chassis
and standard value in normal state 2 ground in wiring harness
(Contact with ground circuit) NGICN1 (female) F PAS (female) C with Resistance Min. 1 M
chassis ground
NGICN1
Voltage
Between F K
20 30 V
Circuit diagram related to steering controller 24 V power supply
D375A-5
20-421
1
4
TROUBLESHOOTING

SERVICE CODE E0146 (ABNORMALITY IN TRANSMISSION CONTROLLER 24 V POWER

SUPPLY SYSTEM)
User code
Service code
E01
E0146
Contents of trouble
Trouble
Abnormality in transmission controller 24 V power supply system

Voltage of 24 V power supply circuit for sensors of transmission controller is below 17 V or above 20 V.
Abnormal current flowed in 24 V power supply circuit for sensors of transmission controller.
Problem that
Work equipment oil pressure cannot be monitored in service mode.
appears on machine
Cause

Defective work equipment
large pump oil pressure senLPP
1
sor
connector
Prepare with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
Possible causes

SPP
small pump oil pressure sen2
connector
sor
Prepare with starting switch OFF, then turn starting
switch ON and carry out troubleshooting.
(Contact with ground circuit) TMCN1 (female) F LPP (female) B or SPP Resistance Min. 1 M
(female) B with chassis ground
TMCN1
Voltage
troller
Between F K
20 30 V
20-422
1
D375A-5
SERVICE CODE E0151 (ABNORMALITY IN SELECTION OF STEERING

CONTROLLER SPECIFICATION)
TROUBLESHOOTING
SERVICE CODE E0151 (ABNORMALITY IN SELECTION OF STEERING CONTROLLER

SPECIFICATION)
User code
Service code
CALL
E0151
Contents of trouble
Trouble
Abnormality in selection of steering controller specification

Internal setting of steering controller specification is different from specification setting signal (Steering controller cannot recognize specification setting normally).

Action of controller Stops steering controller from outputting all signals.
Machine does not move at all.
Problem that
appears on machine
Cause
Defective adjustment of
steering controller
After adjustment mode is executed, if service code changes to P (to

indicate that trouble is repaired), system is normal.
Adjustment code:
5A [Check of specification code (Steering controller)]
Possible causes
ness
and standard val- 2 (Disconnection in wiring or
ue in normal state
defective contact in connec- Wiring harness between NGICN3 (female) J Resistance Max. 1
chassis ground
tor)
NGICN3
Voltage
Between J chassis ground
Max. 1 V
Circuit diagram related to steering controller specification selection signal
D375A-5
20-423
1
TROUBLESHOOTING

User code
Service code
CALL03
E0152
Trouble

Contents of trouble Steering controller detected abnormality in S-NET.

Shoe slip control (SSC) function may not work.

Problem that
Related information
Possible causes
20-424
1

Cause

Carry out troubleshooting for service code [E0101].
D375A-5
TROUBLESHOOTING
SERVICE CODE E0160 (ABNORMALITY IN TRANSMISSION CONTROLLER ROM)

SERVICE
(ABNORMALITY
IN STEERING CONTROLLER ROM)
SERVICE
CODECODE
E0160E0161
(ABNORMALITY
IN TRANSMISSION
SERVICE CODE E0160 (ABNORMALITY IN TRANSMISSION CONTROLLER ROM)

User code
Service code
E01
E0160
Trouble
Abnormality in transmission controller ROM

Contents of trouble Information in transmission controller ROM (non-volatile memory) is abnormal.
Action of controller Sets internal adjustment values to default.

Problem that
Gear shifting feeling of transmission may become bad.
appears on machine
Cause
Possible causes
Since trouble is in system, troubleshooting cannot be carried out.
and standard valDefective transmission con(If there is not visible trouble in machine, controller may be used as it
ue in normal state 1 troller
is.)
SERVICE CODE E0161 (ABNORMALITY IN STEERING CONTROLLER ROM)

User code
Service code
E02
E0161
Trouble
Abnormality in steering controller ROM

Contents of trouble Information in steering controller ROM (non-volatile memory) is abnormal.

Sets internal adjustment values to default.
Steering performance may lower.

Problem that
appears on machine Braking performance may lower.
Cause
Possible causes
Since
trouble is in system, troubleshooting cannot be carried out.
and standard val1
Defective
steering
controller
(If
there
is not visible trouble in machine, controller may be used as it
ue in normal state
is.)
D375A-5
20-425
1
TROUBLESHOOTING
SERVICE CODE E0164 [ABNORMALITY IN NETWORK SYSTEM (TRANSMISSION)]

User code
Service code
CALL03
E0164
Trouble
Abnormality in network system (transmission)

Contents of trouble Transmission controller detected abnormality in S-NET.


Problem that
Related information

Cause

ness
Wiring harness between CN1 (female) B
Resistance Max. 1
TMCN2 (female) K
defective contact in connecWiring harness between CN1 (female) @
tor)
Resistance Max. 1
TMCN2 (female) U
Possible causes

Short circuit of wiring harness between CN1
(Contact with ground circuit) (female) B TMCN2 (female) K with chassis Resistance Min. 1 M
ground

(caution module)

troller
20-426
1
Short circuit of wiring harness between CN1
(female) B TMCN2 (female) K with chassis
ground
Voltage
Max. 1 V
CN2
Voltage
Between B @
69V
TMCN2
Voltage
Between K U
69V
D375A-5
TROUBLESHOOTING
D375A-5
20-427
1
TROUBLESHOOTING
SERVICE CODE E0176 (DISCONNECTION IN BATTERY RELAY SYSTEM)
SERVICE CODE E0176 (DISCONNECTION IN BATTERY RELAY SYSTEM)

User code
Service code
E0176
Trouble
Disconnection in battery relay system

Contents of trouble When signal is output to battery relay circuit, current does not flow.
Action of controller Stops outputting to battery relay circuit.

Problem that
Trouble may occur in writing data in each controller ROM (non-volatile memory).
appears on machine
Related information
Outputting to battery relay (Voltage) can be checked in monitoring mode.

(Code dA: Battery relay drive voltage)
Method of reproducing service code: Turn starting switch ON and OFF.
Cause
Defective battery relay

(Internal disconnection)

Battery relay
Continuity
Between terminals BR E
There is continuity.

ness
Wiring harness between NGICN3 (female) 4
Resistance Max. 1
chassis ground
defective contact in connecPossible causes
Wiring harness between battery relay terminal
tor)
and standard valResistance Max. 1
E chassis ground
ue in normal state
NGICN3 (female) 4 battery relay terminal
Voltage Max. 1 V
BR with chassis ground

NGICN3 (female)
Continuity
Between 4 chassis ground
Circuit diagram related to battery relay
20-428
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0177 (SHORT CIRCUIT IN BATTERY RELAY SYSTEM)
SERVICE CODE E0177 (SHORT CIRCUIT IN BATTERY RELAY SYSTEM)

User code
Service code
E0177
Trouble
Short circuit in battery relay system

Contents of trouble When signal is output to battery relay circuit, abnormal current flowed.
Action of controller Stops outputting to battery relay circuit.

Problem that
Trouble may occur in writing data in each controller ROM (non-volatile memory).
appears on machine
Related information
Outputting to battery relay (Voltage) can be checked in monitoring mode.

(Code dA: Battery relay drive voltage)
Method of reproducing service code: Turn starting switch ON and OFF.
Cause


Battery relay
Continuity/Resistance
Between terminals BR E
Between terminal BR chassis

ground
Min. 1 M
Possible causes
and standard valwithout turning starting switch ON.
ue in normal state 2 ground in wiring harness
(Contact with ground circuit) NGICN3 (female) 4 battery relay terminal Resistance Min. 1 M
BR with chassis ground
NGICN3
Starting switch
Voltage
Between 4 chassis
ground
ON
20 30 V
Circuit diagram related to battery relay
D375A-5
20-429
1
TROUBLESHOOTING
SERVICE CODE E0178 (DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)

User code
Service code
E02
E0178
Trouble
Disconnection in neutral safety relay system

Contents of trouble When GND signal for neutral safety relay circuit is turned off, 24 V is not generated.

Stops outputting GND signal for neutral safety relay circuit.
Problem that
Engine cannot be started.
appears on machine
Outputting to neutral safety relay (Voltage) can be checked in monitoring mode.

(Code dN: Neutral safety relay drive voltage)
Related information
Turn starting switch ON and operate parking brake lever (LOCK position).
This service code detects abnormality on primary side (coil side) of neutral safety relay and cannot
detect abnormality on secondary side (contact side).
Cause
1
(CB3)
Defective neutral safety re2 lay
Possible causes

chassis ground.
NSF (Male)
Resistance
Between 1 2
200 400

ness
Wiring harness between TMCN2 (female) 8
Resistance Max. 1
NSF (female) 2
defective contact in connecWiring harness between NSF (female) 1
tor)
Resistance Max. 1
CB3 (1)
TMCN2 (female) 8 NSF (female) 2 with
(Contact with ground circuit) chassis ground
Short circuit of wiring harness between NSF
(female) 1 CB3 (1) with chassis ground
Resistance Min. 1 M
Resistance Min. 1 M
5
20-430
1
(5)
Defective transmission controller
TMCN2
Parking brake lever
Voltage
Between 8 chassis
ground
When locked
Max. 1 V
When free
20 30 V
D375A-5
TROUBLESHOOTING
Circuit diagram related to neutral safety relay
D375A-5
20-431
1
TROUBLESHOOTING
SERVICE CODE E0179 (SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)

User code
Service code
E02
E0179
Trouble
Short circuit in neutral safety relay system

Contents of trouble When GND signal for neutral safety relay circuit is turned off, abnormal current flowed.

Stops outputting GND signal for neutral safety relay circuit.
Problem that
appears on machine
Outputting to neutral safety relay (Voltage) can be checked in monitoring mode.

(Code dN: Neutral safety relay drive voltage)
Related information
Turn starting switch ON and operate parking brake lever (LOCK position).
This service code detects abnormality on primary side (coil side) of neutral safety relay and cannot
Cause
Defective neutral safety re1 lay

Possible causes
ue in normal state

NSF (male)
Resistance
Between 1 2
200 400
TMCN2 (female) 8 NSF (female) 2 with
chassis ground
Voltage
Max. 1 V
3
20-432
1
(5)
TMCN2
Parking brake lever
Voltage
Between 8 chassis
ground
When locked
Max. 1 V
When free
20 30 V
D375A-5
TROUBLESHOOTING
Circuit diagram related to neutral safety relay
D375A-5
20-433
1
TROUBLESHOOTING
SERVICE CODE E0211 (ABNORMAL TORQUE CONVERTER OIL TEMPERATURE)
SERVICE CODE E0211 (ABNORMAL TORQUE CONVERTER OIL TEMPERATURE)

User code
Service code
E0211
Trouble
Abnormal torque converter oil temperature

Contents of trouble Torque converter oil temperature is above about 130C.
Flashes caution lamp and turns on caution buzzer (Caution function of torque converter oil temperature gauge).
System does not take any particular action. If machine is used without removing cause of trouble,
Problem that
appears on machine
however, mechanical trouble may occur.
Related information
Torque converter oil temperature can be checked in monitoring mode.

(Code 77: Torque converter oil temperature)
Method of reproducing service code: Turn starting switch ON and start engine
Cause
Overheating of torque con1 verter oil

(when system is normal)
Since overheating of torque converter oil is detected, check cause and

damage of machine and repair.
Check torque converter oil temperature gauge. If it does not indicate
real oil temperature, carry out troubleshooting for monitor panel (Emode).
Possible causes
Defective torque converter
and standard val2
oil temperature sensor and
ue in normal state
gauge system
20-434
1

temperature gauge
Lighting segment
Voltage
7th
Above 130C
6th
Below approx. 130C
5th
Below approx. 120C
4th
Below approx. 116C
3rd
Below approx. 110C
2nd
Below approx. 90C
1st
Below approx. 50C

(If there is not visible trouble in machine, controller may be used as it
is.)
D375A-5
SERVICE CODE E0212 (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP

SOLENOID SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0212 (SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID

SYSTEM)
User code
Service code
E01
E0212
Trouble
Short circuit in torque converter lock-up solenoid system

Contents of trouble Abnormal current flowed when signal is output to torque converter lock-up solenoid.
Action of controller Stops outputting to torque converter lock-up solenoid.

Problem that
Torque converter lock-up solenoid does not work.
appears on machine
Outputting to torque converter lock-up solenoid (Voltage) can be checked in monitoring mode.
(Code dL: Lock-up solenoid drive voltage)
Related information Method of reproducing service code: Start engine, turn lock-up switch ON, and drive machine.
When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start traveling.
Cause
1 lock-up solenoid

653 (male)
Resistance
Between 1 2
30 80
Min. 1 M

Possible causes

(Contact with ground circuit) TMCN3 (female) \ 653 (female) 1 with
chassis ground
Short circuit in wiring harness
3
(with another wiring harness)
Resistance Min. 1 M

TMCN3 (female) \ 653 (female) 1 with wirResistance Min. 1 M
ing harness between TMCN3 (female) M
653 (female) 2
TMCN3 (female)
Resistance
Between \ M
30 80
Between \ chassis ground
Min. 1 M
Circuit diagram related to torque converter lock-up solenoid
D375A-5
20-435
1
SERVICE CODE E0213 (DISCONNECTION IN TORQUE CONVERTER LOCK-UP

SOLENOID SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0213 (DISCONNECTION IN TORQUE CONVERTER LOCK-UP

SOLENOID SYSTEM)
User code
Service code
E01
E213
Trouble
Disconnection in torque converter lock-up solenoid system

Contents of trouble Current does not flow when signal is output to torque converter lock-up solenoid.
Action of controller Stops outputting to torque converter lock-up solenoid.

Problem that
Torque converter lock-up solenoid does not work.
appears on machine
Outputting to torque converter lock-up solenoid (Voltage) can be checked in monitoring mode.
(Code dL: Lock-up solenoid drive voltage)
Cause
1 lock-up solenoid

653 (male)
Resistance
Between 1 2
30 80

ness
Wiring harness between TMCN3 (female) \
Resistance Max. 1
653 (female) 1
Possible causes
defective contact in connecand standard valWiring harness between TMCN3 (female) M
tor)
Resistance Max. 1
ue in normal state
653 (female) 2
Short circuit of TMCN3 (female) \ 653 (female) 1 with chassis ground
Voltage
Max. 1 V
TMCN3 (female)
Resistance
troller
Between \ M
30 80
Circuit diagram related to torque converter lock-up solenoid
20-436
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0221 (DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE

SENSOR SYSTEM)

SENSOR SYSTEM)
User code
Service code
E01
E0221
Trouble
Disconnection or short circuit in pitch angle sensor system)

Contents of trouble Signal voltage of pitch angle sensor circuit is below 0.15 V or above 4.85 V.
Action of controller Stops auto shift-down function.

Problem that
appears on machine Auto shift-down function does not work.
Since pitch angle sensor signal is input to both transmission controller and steering controller, related
codes may be displayed simultaneously, depending on troubled part.
(Related code: E0721)
Related information
Inputting from pitch angle revolution sensor (Voltage) can be checked in monitoring mode.
(Code A8: Pitch angle sensor voltage)
When only service code [E0221] is displayed
Cause
Possible causes
ness
defective contact in connec- Wiring harness between TMCN2 (female) 1 Resistance Max. 1
circuit branch point
tor)
TMCN1
Voltage
troller
0.15 4.85 V
When service codes [E0221] and [E0731] are displayed simultaneously

Cause
1
Defective sensor 24 V power See if service code [E0145] is displayed. If it is displayed, carry out
supply system
troubleshooting for it first.
Defective pitch angle sensor
2
(Internal trouble)
PAS
Voltage
Between B A
Possible causes
0.15 4.85 V

ness
Wiring harness between PAS (female) B
Resistance Max. 1
circuit branching point
defective contact in connecWiring harness between PAS (male) C
tor)
Resistance Max. 1
NGICN1 (female) F
Short circuit of wiring harness between PAS
(Contact with ground circuit) (female) B TMCN1 (female) 1 NGICN1 Resistance Min. 1 M
(female) C with chassis ground
D375A-5
20-437
1
TROUBLESHOOTING

SENSOR SYSTEM)
Circuit diagram related to pitch angle sensor
20-438
1
D375A-5
SERVICE CODE E0225 (SLIP OF POWER TRAIN CLUTCH)

SERVICE CODE E0230 [ABNORMALITY IN BOTH FORWARD-REVERSE
POTENTIOMETER
SYSTEMS
(1)]
SERVICE CODE E0225 (SLIP
OF POWER TRAIN
CLUTCH)
TROUBLESHOOTING
SERVICE CODE E0225 (SLIP OF POWER TRAIN CLUTCH)

User code
Service code
E02
E0225
Contents of trouble
Trouble
Slip of power train clutch

When torque converter is locked up, transmission speed calculated from engine speed is different
more than 200 rpm from real speed.
Action of controller Flashes caution lamp and turns on caution buzzer.

Problem that
Auto shift-down function does not work.
appears on machine
Engine speed (rpm) and transmission speed (rpm) can be checked in monitoring mode.
(Code 99: Engine speed, Code 7o: Transmission speed)
Cause
Slip of power train clutch

1
(When system is normal)
Defective engine speed senPossible causes
2
sor system
and standard value in normal state 3 Defective transmission
speed sensor system
4
Since slip of clutch is detected, check cause and damage of machine

and repair.
See if service codes [EC121], [E0930], and [E0931] are displayed. If
they are displayed, carry out troubleshooting for them.
See if service codes [E0932] and [E0933] are displayed. If they are
displayed, carry out troubleshooting for them.

Defective transmission con(If there is not visible trouble in machine, controller may be used as it
troller
is.)

POTENTIOMETER SYSTEMS (1)]
User code
Service code
CALL
E0230
Trouble
Abnormality in both forward-reverse potentiometer systems (1)

Service codes [E0233] and [E0234] are displayed simultaneously for forward-reverse potentiometer
Contents of trouble
systems 1 and 2.


Problem that
appears on machine Once machine is stopped, it cannot travel any more.
Inputting from forward-reverse potentiometers (Voltage) can be checked in monitoring mode.
(Code L3: Voltage of forward-reverse potentiometer 1)
Related information
Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Forward-reverse).
Possible causes
D375A-5
Cause
Carry out troubleshooting for service codes [E0233] and [E0244].
20-439
1
TROUBLESHOOTING
SERVICE CODESERVICE
E0231 [ABNORMALITY
IN BOTH
FORWARD-REVERSE
POTENTIOMETER
SYSTEMS (2)]
CODE E0231
[ABNORMALITY
IN BOTH
FORWARD-REVERSE
POTENTIOMETER
SYSTEMS(2)]
(3)]
POTENTIOMETER
SYSTEMS

User code
Service code
CALL
E0231
Contents of trouble
Trouble

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

Problem that
Related information
Possible causes
Cause

User code
Service code
CALL
E0232
Contents of trouble
Trouble

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

Problem that
Related information
Possible causes
20-440
1
Cause
D375A-5
SERVICE CODE E0233 (DISCONNECTION OR SHORT CIRCUIT IN FORWARDREVERSE POTENTIOMETER 1 SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0233 (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE

POTENTIOMETER 1 SYSTEM)
User code
Service code
CALL03
E0233
Trouble
Disconnection or short circuit in forward-reverse potentiometer 1 system

Contents of trouble Signal voltage of forward-reverse potentiometer 1 (FR3) is below 0.5 V or above 4.5 V.

Action of controller Continues controlling with signal of forward-reverse potentiometer 2 system (FR4).
Problem that
appears on machine Once machine is stopped, travel is limited to F1 and R1.
Inputting from forward-reverse potentiometer 1 (FR3) (Voltage) can be checked in monitoring mode.
(Code L3: Voltage of froward-reverse potentiometer 1)
Related information
Turn starting switch ON and operate PCCS lever (Forward-Reverse travel).
Cause
1
supply system
potentiometer 1
2
(Internal disconnection or
short circuit)
Possible causes
TL1 (male)
Between L J
Between K L
Resistance
2 k 20%
Between K J

ness
Wiring harness between TMCN1 (female) L
Resistance Max. 1
TL1 (female) L
defective contact in connecWiring harness between TMCN1 (female) 2
tor)
Resistance Max. 1
TL1 (female) K
(Contact with ground circuit) TMCN1 (female) 2 TL1 (female) K with
Resistance Min. 1 M
chassis ground

troller
D375A-5

TMCN1 (female) 2 TL1 (female) K with
chassis ground
Voltage
Max. 1 V
TMCN1
Voltage
Between 2 K
0.5 4.5 V
20-441
1
TROUBLESHOOTING
Circuit diagram related to forward-reverse potentiometers
20-442
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0234 (DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE

User code
Service code
CALL03
E0234
Trouble
Disconnection or short circuit in forward-reverse potentiometer 2 system

Contents of trouble Signal voltage of forward-reverse potentiometer 2 (FR4) is below 0.5 V or above 4.5 V.

Action of controller Continues controlling with signal of forward-reverse potentiometer 1 system (FR3).
Problem that
Inputting from forward-reverse potentiometer 2 (FR4) (Voltage) can be checked in monitoring mode.
Related information
Cause
1
supply system
potentiometer 2
2
short circuit)
Possible causes
TL1 (male)
Between O Q
Between P O
Resistance
2 k 20%
Between P Q

ness
Wiring harness between TMCN1 (female) L
Resistance Max. 1
TL1 (female) O
defective contact in connecWiring harness between TMCN1 (female) I
tor)
Resistance Max. 1
TL1 (female) P
(Contact with ground circuit) TMCN1 (female) I TL1 (female) P with
Resistance Min. 1 M
chassis ground

troller
D375A-5

TMCN1 (female) I TL1 (female) P with
chassis ground
Voltage
Max. 1 V
TMCN1
Voltage
Between I K
0.5 4.5 V
20-443
1
TROUBLESHOOTING
SERVICE CODE E0235 (DEVIATION OF FORWARD-REVERSE POTENTIOMETER

SYSTEM SIGNALS)
Circuit diagram related to forward-reverse potentiometers
SERVICE CODE E0235 (DEVIATION OF FORWARD-REVERSE POTENTIOMETER

SYSTEM SIGNALS)
User code
Service code
CALL03
E0235
Trouble
Deviation of forward-reverse potentiometer system signals

Total signal voltages of forward-reverse potentiometers 1 (FR3) and 2 (FR4) is below 4.41 V or above
Contents of trouble
5.59 V.
Continues controlling with normal signal of forward-reverse potentiometer 1 (FR3) system or 2 (FR4)
system.
Problem that
Related information
Possible causes
20-444
1
Cause
D375A-5
TROUBLESHOOTING
SERVICE CODE E0236 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-UP SWITCH

SYSTEMS)

SYSTEMS)
User code
Service code
E02
E0236
Trouble
Disconnection or short circuit in shift-up switch systems

Contents of trouble Signals of both shift-up switch circuit systems are turned ON or OFF simultaneously.

Assumes that switch is not pressed.
Transmission gear cannot be shifted up.

Problem that
NO and NC signals of both switch systems are for detecting operation and error respectively.
Inputting from shift-up switch (ONOFF) can be checked in monitoring mode.
Related information
(Code L5: Transmission controller input 1)
Method of reproducing service code: Turn starting switch ON and operate shift-up switch.
Cause

Defective shift-up switch

1 (Internal disconnection or
short circuit)
TL1 (male)
Shift-up switch
OFF (Pressed)
ON (Released)
Resistance between
NU
Max. 1
Min. 1 M
Resistance between
NB
Min. 1 M
Max. 1


Resistance Max. 1
TL1 (female) U
Wiring harness between TMCN2 (female) [
Resistance Max. 1
TL1 (female) B
Resistance Max. 1
@ TL1 (female) N
Possible causes
and standard valShort circuit with chassis
TMCN1 (female) 6 TL1 (female) U with
chassis ground
TMCN2 (female) [ TL1 (female) B with
chassis ground
Resistance Min. 1 M
Resistance Min. 1 M

TMCN1 (female) 6 TL1 (female) U with
chassis ground
Voltage
Max. 1 V

TMCN2 (female) [ TL1 (female) B with
chassis ground
Voltage
Max. 1 V
TMCN1, TMCN2
troller
Voltage between TMCN1
6 TMCN1 4, @
[ TMCN1 4, @
D375A-5
Shift-up switch
OFF (Released)
ON (Pressed)
Max. 1 V
5 11 V
5 11 V
Max. 1 V
20-445
1
(5)
TROUBLESHOOTING

SYSTEMS)
Circuit diagram related to shift-up switch and shift-down switch
20-446
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN

SWITCH SYSTEMS)
SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN SWITCH

SYSTEMS)
User code
Service code
E02
E0237
Trouble
Disconnection or short circuit in shift-down switch systems

Contents of trouble Signals of both shift-down switch circuit systems are turned ON or OFF simultaneously.

Transmission gear cannot be shifted down.

Problem that
Inputting from shift-down switch (ONOFF) can be checked in monitoring mode.
Related information
Method of reproducing service code: Turn starting switch ON and operate shift-down switch.
Cause

Defective shift-down switch

short circuit)
TL1 (male)
Shift-up switch
OFF (Pressed)
ON (Released)
Resistance between
DV
Max. 1
Min. 1 M
Resistance between
DC
Min. 1 M
Max. 1

Wiring harness between TMCN3 (female) I

Resistance Max. 1
TL1 (female) V
Wiring harness between TMCN3 (female) S
Resistance Max. 1
TL1 (female) C
Resistance Max. 1
@ TL1 (female) D
Possible causes
and standard valShort circuit with chassis
TMCN3 (female) I TL1 (female) V with
chassis ground
TMCN3 (female) S TL1 (female) C with
chassis ground
Resistance Min. 1 M
Resistance Min. 1 M

TMCN3 (female) I TL1 (female) V with
chassis ground
Voltage
Max. 1 V

TMCN3 (female) S TL1 (female) C with
chassis ground
Voltage
Max. 1 V
TMCN1, TMCN3
troller
I TMCN1 4, @
S TMCN1 4, @
D375A-5
Shift-up switch
OFF (Released)
ON (Pressed)
Max. 1 V
5 11 V
5 11 V
Max. 1 V
20-447
1
(5)
TROUBLESHOOTING
SERVICE CODE E0237 (DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN

SWITCH SYSTEMS)
Circuit diagram related to shift-up switch and shift-down switch
20-448
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0238 (DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE

LEVER SWITCH SYSTEMS)

User code
CALL03
Contents of trouble
Problem that
appears on machine
Related information
Service code
Disconnection or short circuit in parking brake lever switch systems
Trouble
E0238
Signals of both parking brake lever switch circuit systems are turned ON or OFF simultaneously.
Assumes that parking brake lever is at FREE position.
Since parking brake switch signal is used by both transmission controller and steering controller, related codes may be displayed simultaneously, depending on troubled part.
(Related codes: E0239, E0781, E0782)
Inputting from parking brake switch (ONOFF) can be checked in monitoring mode.
Method of reproducing service code: Turn starting switch ON and operate parking brake lever.

Cause
ness
Wiring harness between TMCN2 (female) H
Resistance Max. 1
defective contact in connecWiring harness between TMCN2 (female) B
Resistance Max. 1
tor)
Possible causes
and standard valcarry out troubleshooting.
ue in normal state
Parking brake lever
TMCN2
At FREE
At LOCK
Between H chassis
troller
Max. 1 V
5 11 V
ground
Between B chassis
5 11 V
Max. 1 V
ground
Possible causes
3
D375A-5

Cause
Defective parking brake leParking brake lever
ver switch
NSW
At FREE
At LOCK
Between A B
Max. 1
Min. 1 M
short circuit)
Between A B
Min. 1 M
Max. 1
Disconnection in wiring harWiring
harness between NSW (female) B
ness
Resistance Max. 1
circuit merging point
(Disconnection in wiring or
Wiring harness between NSW (female) C
Resistance Max. 1
defective contact in connec- circuit merging point
tor)
Wiring harness between NSW (female) A
Resistance Max. 1
chassis ground
Short
circuit of wiring harness between NSW
(female) B TMCN1 (female) H NGICN2 Resistance Min. 1 M
ground in wiring harness
(female) 5 with chassis ground
Short circuit of wiring harness between NSW
(female) C TMCN1 (female) B NGICN2 Resistance Min. 1 M
(female) E with chassis ground
Short
(female) B TMCN1 (female) H NGICN2
Voltage
Max. 1 V
source in wiring harness
(female) 5 with chassis ground
(female) C TMCN1 (female) B NGICN2
Voltage
Max. 1 V
(female) E with chassis ground
20-449
1
(5)
TROUBLESHOOTING

Circuit diagram related to parking brake switch
20-450
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0239 (DISAGREEMENT OF PARKING BRAKE LEVER SWITCH

SYSTEM SIGNALS)

SYSTEM SIGNALS)
User code
Service code
CALL03
E0239
Contents of trouble
Trouble
Disagreement of parking brake lever switch system signals

Switch input signal of transmission controller disagrees with communication signal from steering controller.

Problem that
Since parking brake switch signal is used by both transmission controller and steering controller and
information is exchanged by S-NET communication, related codes may be displayed simultaneously,
depending on troubled part.
(Related codes: E0101, E0104, E0105, E0152, E0164, E0238, E0781, E0782)
Related information
(Code L5: Transmission controller switch input 1)
Cause
See if service codes [E0101], [E0104], [E0105], [E0152], and [E0162]

Defective S-NET communi1
are displayed. If they are displayed, carry out troubleshooting for them
cation system
first.
Possible causes
and standard value in normal state 2 Defective parking brake lever switch signal system
3
D375A-5
displayed, carry out troubleshooting for them first.
(Service code [E0782] is same as [E0239].)
Defective transmission conSince trouble is in system, troubleshooting cannot be carried out.

troller
20-451
1
TROUBLESHOOTING
SERVICE CODE E0250 (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH

ECMV SYSTEM)
SERVICE CODE E0250 (DISCONNECTION IN TRANSMISSION FORWARD CLUTCH

ECMV SYSTEM)
User code
Service code
CALL03
E0250
Trouble
Disconnection in transmission forward clutch ECMV system

Contents of trouble When signal is output to transmission forward clutch solenoid circuit, current does not flow.

Action of controller Stops outputting to transmission forward clutch solenoid circuit.
Problem that
appears on machine Once machine is stopped, travel is limited to R1.
Outputting to forward clutch solenoid (Current) can be checked in monitoring mode.
(Code P5, c5: Forward clutch ECMV output current)
Related information Method of reproducing service code: Start engine and drive forward.
When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not travel forward.
Cause
Defective forward clutch so1 lenoid
Possible causes

SFT (male)
Resistance
Between 1 2
5 15

ness
Wiring harness between TMCN3 (female) Y
Resistance Max. 1
SFT (female) 1
defective contact in connecWiring harness between TMCN3 (female) C
tor)
Resistance Max. 1
SFT (female) 2
TMCN3 (female) Y SFT (female) 1 with
chassis ground
Voltage
Max. 1 V

Resistance
troller
TMCN3 (female)
Between Y C
5 15
Circuit diagram related to transmission forward clutch ECMV
20-452
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0251 (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH

ECMV SYSTEM)
SERVICE CODE E0251 (SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0251
Trouble
Short circuit in transmission forward clutch ECMV system

Contents of trouble When signal was output to transmission forward clutch solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to transmission forward clutch solenoid circuit.
Problem that
Outputting to forward clutch solenoid (Current) can be checked in monitoring mode.
(Code P5, c5: Forward clutch ECMV output current)
When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not travel forward.
Cause
Defective forward clutch so1 lenoid

SFT (male)
Resistance
Between 1 2
5 15
Min. 1 M

Possible causes

(Contact with ground circuit) TMCN3 (female) Y SFT (female) 1 with
chassis ground
3
Resistance Min. 1 M

TMCN3 (female) Y SFT (female) 1 with
Resistance Min. 1 M
wiring harness between TMCN3 (female) C
SFT (female) 2
TMCN3 (female)
Resistance
Between Y C
5 15
Between Y chassis ground
Min. 1 M
D375A-5
20-453
(7)
1
TROUBLESHOOTING
SERVICE CODE E0252 (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH

ECMV SYSTEM)
SERVICE CODE E0252 (DISCONNECTION IN TRANSMISSION REVERSE CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0252
Trouble
Disconnection in transmission reverse clutch ECMV system

Contents of trouble When signal is output to transmission reverse clutch solenoid circuit, current does not flow.

Action of controller Stops outputting to transmission reverse clutch solenoid circuit.
Problem that
appears on machine Once machine is stopped, travel is limited to F1.
Outputting to reverse clutch solenoid (Current) can be checked in monitoring mode.
(Code P6, c6: Reverse clutch ECMV output current)
Related information Method of reproducing service code: Start engine and drive in reverse.
When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that machine will not start.
Cause
Defective reverse clutch so1 lenoid
Possible causes

SRT (male)
Resistance
Between 1 2
5 15

ness
Wiring harness between TMCN3 (female) O
Resistance Max. 1
SRT (female) 1
tor)
Resistance Max. 1
SRT (female) 2
TMCN3 (female) O SRT (female) 1 with
chassis ground
Voltage
Max. 1 V

Resistance
troller
TMCN3 (female)
Between O 3
5 15
Circuit diagram related to transmission reverse clutch ECMV
20-454
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0253 (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH

ECMV SYSTEM)
SERVICE CODE E0253 (SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0253
Trouble
Short circuit in transmission reverse clutch ECMV system

Contents of trouble When signal was output to transmission reverse clutch solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to transmission reverse clutch solenoid circuit.
Problem that
Outputting to reverse clutch solenoid (Current) can be checked in monitoring mode.
(Code P6, c6: Reverse clutch ECMV output current)
Cause
Defective reverse clutch so1 lenoid

SRT (male)
Resistance
Between 1 2
5 15
Min. 1 M

Possible causes

(Contact with ground circuit) TMCN3 (female) O SRT (female) 1 with
chassis ground
3
Resistance Min. 1 M

TMCN3 (female) O SRT (female) 1 with
Resistance Min. 1 M
wiring harness between TMCN3 (female) 3
SRT (female) 2
TMCN3 (female)
Resistance
Between O 3
5 15
Between O chassis ground
Min. 1 M
D375A-5
20-455
(7)
1
TROUBLESHOOTING
SERVICE CODE E0254 (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV

SYSTEM)
SERVICE CODE E0254 (DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0254
Trouble
Disconnection in transmission 1st clutch ECMV system

Contents of trouble When signal is output to transmission 1st clutch solenoid circuit, current does not flow.

Action of controller Stops outputting to transmission 1st clutch solenoid circuit.
Problem that
appears on machine
Outputting to 1st clutch solenoid (Current) can be checked in monitoring mode.

(Code P7, c7: 1st clutch ECMV output current)
Related information Method of reproducing service code: Start engine and drive in F1 or R1.
Cause
Defective 1st clutch solenoid
1
Possible causes

S1T (male)
Resistance
Between 1 2
5 15

ness
Wiring harness between TMCN3 (female) E
Resistance Max. 1
S1T (female) 1
tor)
Resistance Max. 1
S1T (female) 2
TMCN3 (female) E S1T (female) 1 with
chassis ground
Voltage
Max. 1 V

troller
TMCN3 (female)
Resistance
Between E C
5 15
Circuit diagram related to transmission 1st clutch ECMV
20-456
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0255 (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV

SYSTEM)
SERVICE CODE E0255 (SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0255
Trouble
Short circuit in transmission 1st clutch ECMV system

Contents of trouble When signal was output to transmission 1st clutch solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to transmission 1st clutch solenoid circuit.
Problem that
appears on machine
Outputting to 1st clutch solenoid (Current) can be checked in monitoring mode.

(Code P7, c7: 1st clutch ECMV output current)
Cause

Possible causes
Defective 1st clutch solenoid

S1T (male)
Resistance
Between 1 2
5 15
Min. 1 M

(Contact with ground circuit) TMCN3 (female) E S1T (female) 1 with
Resistance Min. 1 M
chassis ground
3

TMCN3 (female) E S1T (female) 1 with
Resistance Min. 1 M
S1T (female) 2
TMCN3 (female)
Resistance
Between E C
5 15
Between E chassis ground
Min. 1 M
D375A-5
20-457
(7)
1
TROUBLESHOOTING
SERVICE CODE E0256 (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV

SYSTEM)
SERVICE CODE E0256 (DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0256
Trouble
Disconnection in transmission 2nd clutch ECMV system

Contents of trouble When signal is output to transmission 2nd clutch solenoid circuit, current does not flow.

Action of controller Stops outputting to transmission 2nd clutch solenoid circuit.
Problem that
Outputting to 2nd clutch solenoid (Current) can be checked in monitoring mode.
(Code P8, c8: 2nd clutch ECMV output current)
Cause
Defective 2nd clutch sole1 noid
Possible causes

S2T (male)
Resistance
Between 1 2
5 15

ness
2 (Disconnection in wiring or Wiring harness between TMCN3 (female) Z Resistance Max. 1
S2T (female) 1
tor)
Resistance Max. 1
S2T (female) 2

troller
TMCN3 (female) Z S2T (female) 1 with
chassis ground
Voltage
Max. 1 V

TMCN3 (female)
Resistance
Between Z 3
5 15
Circuit diagram related to transmission 2nd clutch ECMV
20-458
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0257 (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV

SYSTEM)
SERVICE CODE E0257 (SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0257
Trouble
Short circuit in transmission 2nd clutch ECMV system

Contents of trouble When signal was output to transmission 2nd clutch solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to transmission 2nd clutch solenoid circuit.
Problem that
Outputting to 2nd clutch solenoid (Current) can be checked in monitoring mode.
(Code P8, c8: 2nd clutch ECMV output current)
Cause
Defective 2nd clutch sole1 noid

S2T (male)
Resistance
Between 1 2
5 15
Min. 1 M

Possible causes

(Contact with ground circuit) TMCN3 (female) Z S2T (female) 1 with
chassis ground
3
Resistance Min. 1 M

TMCN3 (female) Z S2T (female) 1 with
Resistance Min. 1 M
wiring harness between TMCN3 (female) 3
S2T (female) 2
TMCN3 (female)
Resistance
Between Z 3
5 15
Between Z chassis ground
Min. 1 M
D375A-5
20-459
(7)
1
TROUBLESHOOTING
SERVICE CODE E0258 (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV

SYSTEM)
SERVICE CODE E0258 (DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0258
Trouble
Disconnection in transmission 3rd clutch ECMV system

Contents of trouble When signal is output to transmission 3rd clutch solenoid circuit, current does not flow.

Action of controller Stops outputting to transmission 3rd clutch solenoid circuit.
Problem that
Outputting to 3rd clutch solenoid (Current) can be checked in monitoring mode.
(Code P9, c9: 3rd clutch ECMV output current)
Cause
Defective 3rd clutch sole1 noid
Possible causes

S3T (male)
Resistance
Between 1 2
5 15

ness
2 (Disconnection in wiring or Wiring harness between TMCN3 (female) 5 Resistance Max. 1
S3T (female) 1
tor)
Resistance Max. 1
S3T (female) 2

troller
TMCN3 (female) 5 S3T (female) 1 with
chassis ground
Voltage
Max. 1 V

TMCN3 (female)
Resistance
Between 5 C
5 15
Circuit diagram related to transmission 3rd clutch ECMV
20-460
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0259 (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV

SYSTEM)
SERVICE CODE E0259 (SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV

SYSTEM)
User code
Service code
CALL03
E0259
Trouble
Short circuit in transmission 3rd clutch ECMV system

Contents of trouble When signal was output to transmission 3rd clutch solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to transmission 3rd clutch solenoid circuit.
Problem that
Outputting to 3rd clutch solenoid (Current) can be checked in monitoring mode.
(Code P9, c9: 3rd clutch ECMV output current)
Cause
Defective 3rd clutch sole1 noid

S3T (male)
Resistance
Between 1 2
5 15
Min. 1 M

Possible causes

(Contact with ground circuit) TMCN3 (female) 5 S3T (female) 1 with
chassis ground
3
Resistance Min. 1 M

TMCN3 (female) 5 S3T (female) 1 with
Resistance Min. 1 M
S3T (female) 2
TMCN3 (female)
Resistance
Between 5 C
5 15
Min. 1 M
D375A-5
20-461
(7)
1
TROUBLESHOOTING
SERVICE CODE E0260 (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD

CLUTCH)
SERVICE CODE E0260 (DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD

CLUTCH)
User code
Service code
CALL03
E0260
Contents of trouble
Trouble
Defective engagement of transmission forward clutch

When signal is output to transmission forward clutch solenoid circuit, fill switch signal is not turned
ON.

Action of controller Judges that transmission is in N (Neutral) when it is set in forward position.
Problem that
Inputting from forward clutch fill switch (ONOFF) can be checked in monitoring mode.
(Code 7H: Transmission fill switch input)
Cause
Defective forward clutch fill
1 switch
Possible causes

Prepare with starting switch OFF, then start engine and carry out
troubleshooting.
FFT (male)
PCCS lever
Resistance
Between 1 chassis
ground
Min. 1 M
F (Forward)
Max. 1
ness
2
(Disconnection in wiring or de- Wiring harness between TMCN1 (female) 5
Resistance Max. 1
fective contact in connector) FFT (female) 1
troubleshooting.
3
4 Defective hydraulic system
TMCN1
PCCS lever
Voltage
Between 5 chassis
ground
20 30 V
F (Forward)
Max. 1 V
If electric system does not have abnormality, hydraulic system may

have. Carry out related troubleshooting (H-mode).
20-462
(7)
1
D375A-5
SERVICE CODE E0261 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION

FORWARD CLUTCH)
TROUBLESHOOTING
SERVICE CODE E0261 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD

CLUTCH)
User code
Service code
CALL03
E0261
Contents of trouble
Trouble
Defective disengagement of transmission forward clutch

When outputting of signal to transmission forward clutch solenoid circuit is stopped, fill switch signal
is not turned OFF.

Action of controller Judges that transmission is in N (Neutral) when it is set in reverse position.
Problem that
Inputting from forward clutch fill switch (ONOFF) can be checked in monitoring mode.
Related information Method of reproducing service code: Start engine and set transmission in neutral.
Cause
Defective forward clutch fill
1 switch
Possible causes

troubleshooting.
FFT (male)
PCCS lever
Resistance
Between 1 chassis
ground
Min. 1 M
F (Forward)
Max. 1

Max.
(Contact with ground circuit) TMCN1 (female) 5 FFT (female) 1 with
Resistance
1
M
chassis ground
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between 5 chassis
ground
20 30 V
F (Forward)
Max. 1 V

D375A-5
20-463
(7)
1
TROUBLESHOOTING
SERVICE CODE E0262 (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE

CLUTCH)
SERVICE CODE E0262 (DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE

CLUTCH)
User code
Service code
CALL03
E0262
Contents of trouble
Trouble
Defective engagement of transmission reverse clutch

When signal is output to transmission reverse clutch solenoid circuit, fill switch signal is not turned
ON.

Action of controller Judges that transmission is in N (Neutral) when it is set in reverse position.
Problem that
Inputting from reverse clutch fill switch (ONOFF) can be checked in monitoring mode.
Cause
Defective reverse clutch fill
1 switch
Possible causes

troubleshooting.
FRT (male)
PCCS lever
Resistance
Between 1 chassis
ground
Min. 1 M
R (Reverse)
Max. 1
ness
2
(Disconnection in wiring or de- Wiring harness between TMCN1 (female) N
Resistance Max. 1
fective contact in connector) FRT (female) 1
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between N chassis
ground
20 30 V
R (Reverse)
Max. 1 V

20-464
(7)
1
D375A-5
SERVICE CODE E0263 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION

REVERSE CLUTCH)
TROUBLESHOOTING
SERVICE CODE E0263 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE

CLUTCH)
User code
Service code
CALL03
E0263
Contents of trouble
Trouble
Defective disengagement of transmission reverse clutch

When outputting of signal to transmission reverse clutch solenoid circuit is stopped, fill switch signal
is not turned OFF.

Action of controller Judges that transmission is in N (Neutral) when it is set in forward position.
Problem that
Inputting from reverse clutch fill switch (ONOFF) can be checked in monitoring mode.
Cause
Defective reverse clutch fill
1 switch
Possible causes

troubleshooting.
FRT (male)
PCCS lever
Resistance
Between 1 chassis
ground
Min. 1 M
R (Reverse)
Max. 1

(Contact with ground circuit) TMCN1 (female) N FRT (female) 1 with
Resistance Max. 1
chassis ground
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between N chassis
ground
20 30 V
R (Reverse)
Max. 1 V

D375A-5
20-465
(7)
1
SERVICE CODE E0264 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST

CLUTCH)
TROUBLESHOOTING
SERVICE CODE E0264 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH)

User code
Service code
CALL03
E0264
Trouble
Defective engagement of transmission 1st clutch

Contents of trouble When signal is output to transmission 1st clutch solenoid circuit, fill switch signal is not turned ON.

Problem that
appears on machine
Inputting from 1st clutch fill switch (ONOFF) can be checked in monitoring mode.
Cause
Defective 1st clutch fill
1 switch
Possible causes

aPrepare with starting switch OFF, then start engine and carry out
troubleshooting.
F1T (male)
PCCS lever
Resistance
Between 1 chassis
ground
Other than F1R1
Min. 1 M
F1R1
Max. 1
Disconnection in wiring har- aPrepare with starting switch OFF, then carry out troubleshooting
ness
2
(Disconnection in wiring or de- Wiring harness between TMCN1 (female) M
Resistance Max. 1
fective contact in connector) F1T (female) 1
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between M chassis
ground
Other than F1R1
20 30 V
F1R1
Max. 1 V

20-466
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0265 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST

CLUTCH)
SERVICE CODE E0265 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST

CLUTCH)
User code
Service code
CALL03
E0265
Contents of trouble
Trouble
Defective disengagement of transmission 1st clutch

When outputting of signal to transmission 1st clutch solenoid circuit is stopped, fill switch signal is not
turned OFF.

Problem that
Inputting from 1st clutch fill switch (ONOFF) can be checked in monitoring mode.
Cause
Defective 1st clutch fill
1 switch
Possible causes

troubleshooting.
F1T (male)
PCCS lever
Resistance
Between 1 chassis
ground
Other than F1R1
Min. 1 M
F1R1
Max. 1
aPrepare with starting switch OFF, then carry out troubleshooting


(Contact with ground circuit) TMCN1 (female) M F1T (female) 1 with
chassis ground
Resistance Min. 1 M
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between M chassis
ground
Other than F1R1
20 30 V
F1R1
Max. 1 V

D375A-5
20-467
(7)
1
SERVICE CODE E0266 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND

CLUTCH)
TROUBLESHOOTING
SERVICE CODE E0266 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH)

User code
Service code
CALL03
E0266
Trouble
Defective engagement of transmission 2nd clutch

Contents of trouble When signal is output to transmission 2nd clutch solenoid circuit, fill switch signal is not turned ON.


Problem that
Inputting from 2nd clutch fill switch (ONOFF) can be checked in monitoring mode.
Cause
Defective 2nd clutch fill
1 switch
Possible causes

troubleshooting.
F2T (male)
PCCS lever
Resistance
Between 1 chassis
ground
Other than F2R2
Min. 1 M
F2R2
Max. 1
ness
2
(Disconnection in wiring or de- Wiring harness between TMCN1 (female) G
Resistance Max. 1
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between G chassis
ground
Other than F2R2
20 30 V
F2R2
Max. 1 V

20-468
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0267 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND

CLUTCH)
SERVICE CODE E0267 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND

CLUTCH)
User code
Service code
CALL03
E0267
Contents of trouble
Trouble
Defective disengagement of transmission 2nd clutch

When outputting of signal to transmission 2nd clutch solenoid circuit is stopped, fill switch signal is
not turned OFF.
Problem that
appears on machine
Inputting from 2nd clutch fill switch (ONOFF) can be checked in monitoring mode.
Cause
Defective 2nd clutch fill
1 switch
Possible causes

troubleshooting.
F2T (male)
PCCS lever
Resistance
Between 1 chassis
ground
Other than F2R2
Min. 1 M
F2R2
Max. 1

Max.
(Contact with ground circuit) TMCN1 (female) G F2T (female) 1 with
Resistance
1
M
chassis ground
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between G chassis
ground
Other than F2R2
20 30 V
F2R2
Max. 1 V

D375A-5
20-469
(7)
1
SERVICE CODE E0268 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD

CLUTCH)
TROUBLESHOOTING
SERVICE CODE E0268 (DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH)

User code
Service code
CALL03
E0268
Trouble
Defective engagement of transmission 3rd clutch

Contents of trouble When signal is output to transmission 3rd clutch solenoid circuit, fill switch signal is not turned ON.


Problem that
Inputting from 3rd clutch fill switch (ONOFF) can be checked in monitoring mode.
Cause
Defective 3rd clutch fill
1 switch
Possible causes

troubleshooting.
F3T (male)
PCCS lever
Resistance
Between 1 chassis
ground
Other than F3R3
Min. 1 M
F3R3
Max. 1
ness
2
(Disconnection in wiring or de- Wiring harness between TMCN1 (female) A
Resistance Max. 1
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between A chassis
ground
Other than F3R3
20 30 V
F3R3
Max. 1 V

20-470
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0269 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD

CLUTCH)
SERVICE CODE E0269 (DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD

CLUTCH)
User code
Service code
CALL03
E0269
Contents of trouble
Trouble
Defective disengagement of transmission 3rd clutch

When outputting of signal to transmission 3rd clutch solenoid circuit is stopped, fill switch signal is not
turned OFF.
Problem that
appears on machine
Inputting from 3rd clutch fill switch (ONOFF) can be checked in monitoring mode.
Cause
Defective 3rd clutch fill
1 switch
Possible causes

troubleshooting.
F3T (male)
PCCS lever
Resistance
Between 1 chassis
ground
Other than F3R3
Min. 1 M
F3R3
Max. 1

(Contact with ground circuit) TMCN1 (female) A F3T (female) 1 with
Resistance Max. 1
chassis ground
troubleshooting.
3
TMCN1
PCCS lever
Voltage
Between A chassis
ground
Other than F3R3
20 30 V
F3R3
Max. 1 V

D375A-5
20-471
(7)
1
SERVICE CODE E0270 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE ENGAGEMENT)]

SERVICE
CODE E0270
E0271 [DOUBLE
TROUBLE
IN TRANSMISSION
CLUTCH (DEFECTIVE
SERVICE
CODE
[DOUBLE
TROUBLE
IN TRANSMISSION
CLUTCH
DISENGAGEMENT)]
(DEFECTIVE ENGAGEMENT)]
TROUBLESHOOTING
SERVICE CODE E0270 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE

ENGAGEMENT)]
User code
Service code
CALL03
E0270
Contents of trouble
Trouble
Double trouble in transmission clutch (Defective engagement)

Following service codes related to transmission clutch are displayed simultaneously.

Either of [E0254] and [E0255] and either of [E0256] and [E0257]
Problem that
appears on machine
Method of reproducing service code: Start engine and drive machine.
Related information When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that ma-
chine will not start.

Cause
Possible causes
Carry out troubleshooting for service codes displayed simultaneously.

[E0254], [E0255], [E0256], [E0257]
SERVICE CODE E0271 [DOUBLE TROUBLE IN TRANSMISSION CLUTCH (DEFECTIVE

DISENGAGEMENT)]
User code
Service code
CALL
E0271
Trouble
Double trouble in transmission clutch (Defective disengagement)

Following service codes related to transmission clutch are displayed simultaneously.

1Either of [E0250] and [E0251] and either of [E0252] and [E0253]
2Either of [E0258] and [E0259] and [E0270]
3[E0260] and [E0262]
Contents of trouble
4[E0261] and [E0263]
5[E0264], [E0266], and [E0268]
6[E0265] and [E0267]
7[E0265] and [E0269]
8[E0267] and [E0269]

Problem that
appears on machine
Related information When troubleshooting by operating clutch, set system in adjustment mode (Code: Co) so that ma-
chine will not start.

Cause
Possible causes
20-472
1
Carry out troubleshooting for service codes displayed simultaneously.

[E0250], [E0251], [E0252], [E0253], [E0258], [E0259],
[E0260], [E0261], [E0262], [E0263], [E0264], [E0265],
[E0266], [E0267], [E0268], [E0269], [E0270]
D375A-5
TROUBLESHOOTING
SERVICE CODE E0306 (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE
SWITCH SYSTEM)
SERVICE CODE E0306 (SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE SWITCH
SYSTEM)
User code
Service code
E02
E0306
Trouble
Short circuit in blade tilt right oil pressure switch system

Contents of trouble Signal of blade tilt right oil pressure switch circuit was kept turned ON for 180 seconds.

Judges that oil pressure switch is turned OFF.
When pitch and dump operation or right dual tilt operation is performed, right single tilt mechanism
Problem that
appears on machine
operates.
Inputting from blade tilt right oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code bH: Blade lever oil pressure switch input)
Related information
Turn starting switch ON (Service code is reproduced after 180 seconds).
Cause
After reproductive operation, if service code P is still displayed (to inDefective operation of lever
dicate that trouble is repaired), lever may have been so operated that
1
(Electric system is normal)
error would be detected.
Defective blade tilt right oil
2 pressure switch
Possible causes
troubleshooting.
TRS (male)
Between 1 2
Blade lever
Resistance
Neutral
Min. 1 M
Right tilt
Max. 1

Max.
(Contact with ground circuit) TMCN2 (female) 6 TRS (female) 1 with
Resistance
1 M
chassis ground
troubleshooting.
4
TMCN2, TMCN1
Blade lever
Voltage
Between TMCN2 6
TMCN1 4, @
Neutral
5 11 V
Right tilt
Max. 1 V
Circuit diagram related to blade tilt right oil pressure switch
D375A-5
20-473
1
(5)
SERVICE CODE E0307 (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE
SWITCH SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0307 (SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH
SYSTEM)
User code
Service code
E02
E0307
Trouble
Short circuit in blade tilt left oil pressure switch system

Contents of trouble Signal of blade tilt left oil pressure switch circuit was kept turned ON for 180 seconds.

Judges that oil pressure switch is turned OFF.
When pitch and dump operation or right dual tilt operation is performed, left single tilt mechanism opProblem that
appears on machine
erates.
Inputting from blade tilt left oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code bH: Blade lever oil pressure switch input)
Related information
Cause
1
Defective blade tilt left oil
2 pressure switch
Possible causes
troubleshooting.
TLS (male)
Between 1 2
Blade lever
Resistance
Neutral
Min. 1 M
Left tilt
Max. 1

Max.
(Contact with ground circuit) TMCN2 (female) F TLS (female) 1 with
Resistance
1 M
chassis ground
troubleshooting.
4
TMCN2, TMCN1
Blade lever
Voltage
Between TMCN2 F
TMCN1 4, @
Neutral
5 11 V
Left tilt
Max. 1 V
Circuit diagram related to blade tilt left oil pressure switch
20-474
1
(5)
D375A-5
TROUBLESHOOTING
SERVICE CODE E0308 (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE
SWITCH SYSTEM)
SERVICE CODE E0308 (SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE
SWITCH SYSTEM)
User code
Service code
E02
E0308
Trouble
Short circuit in ripper lift raise oil pressure switch system

Contents of trouble Signal of ripper lift raise oil pressure switch circuit was kept turned ON for 60 seconds.
Action of controller Judges that oil pressure switch is turned OFF.

Problem that
Shoe slip control (SSC) function does not work normally.
appears on machine
Inputting from ripper lift raise oil pressure switch (ONOFF) can be checked in monitoring mode.
(Code R7: Ripper lever oil pressure switch input)
Related information
Cause
1
Defective ripper lift raise oil
2 pressure switch
Possible causes
troubleshooting.
RPU (male)
Between 1 2
Ripper lever
Resistance
Neutral
Min. 1 M
Raise
Max. 1

Max.
(Contact with ground circuit) NGICN2 (female) 3 RPU (female) 1 with Resistance
1 M
chassis ground
troubleshooting.
NGICN2, NGICN1
Ripper lever
Voltage
Between NGICN2 3
NGICN1 4, @
Neutral
5 11 V
Raise
Max. 1 V
Circuit diagram related to ripper lift raise oil pressure switch
D375A-5
20-475
1
(5)
TROUBLESHOOTING
SERVICE CODE E0309 (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE
SWITCH SYSTEM)
SERVICE CODE E0309 (SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE
SWITCH SYSTEM)
User code
Service code
E02
E0309
Trouble
Short circuit in ripper lift lower oil pressure switch system

Contents of trouble Signal of ripper lift lower oil pressure switch circuit was kept turned ON for 60 seconds.

Problem that
appears on machine
Inputting from ripper lift lower oil pressure switch (ONOFF) can be checked in monitoring mode.
Related information
Cause
1
Defective ripper lift lower oil
2 pressure switch
Possible causes
troubleshooting.
RPD (male)
Between 1 2
Ripper lever
Resistance
Neutral
Min. 1 M
Lower
Max. 1

Max.
(Contact with ground circuit) NGICN1 (female) N RPD (female) 1 with Resistance
1 M
chassis ground
troubleshooting.
NGICN1
Ripper lever
Voltage
Between NGICN1 N
4, @
Neutral
5 11 V
Lower
Max. 1 V
Circuit diagram related to ripper lift lower oil pressure switch
20-476
1
(5)
D375A-5
TROUBLESHOOTING
SERVICE CODE E0310 (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH
SYSTEM)
SERVICE CODE E0310 (SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH
SYSTEM)
User code
Service code
E02
E0310
Trouble
Short circuit in ripper tilt-in oil pressure switch system

Contents of trouble Signal of ripper tilt-in oil pressure switch circuit was kept turned ON for 60 seconds.

Problem that
appears on machine
Inputting from ripper tilt-in oil pressure switch (ONOFF) can be checked in monitoring mode.
Related information
Cause
1
Defective ripper tilt-in oil
2 pressure switch
Possible causes
troubleshooting.
RTI (male)
Between 1 2
Ripper lever
Resistance
Neutral
Min. 1 M
Tilt-in
Max. 1

Max.
(Contact with ground circuit) NGICN1 (female) H RTI (female) 1 with
Resistance
1 M
chassis ground
troubleshooting.
NGICN1
Ripper lever
Voltage
Between NGICN1 H
4, @
Neutral
5 11 V
Tilt-in
Max. 1 V
Circuit diagram related to ripper tilt-in oil pressure switch
D375A-5
20-477
1
(5)
TROUBLESHOOTING
SERVICE CODE E0311 (DISCONNECTION OR SHORT CIRCUIT IN BLADE PITCH

SWITCH SYSTEMS)

SWITCH SYSTEMS)
User code
Service code
E02
E0311
Trouble
Disconnection or short circuit in blade pitch switch systems

Contents of trouble Signals of both blade pitch switch circuit systems are turned ON or OFF simultaneously.

Problem that
Blade does not pitch (When pitching operation is performed, blade tilts).
appears on machine
Inputting from blade pitch switch (ONOFF) can be checked in monitoring mode.
Related information
(Code bD: Blade lever knob switch input)
Method of reproducing service code: Turn starting switch ON and operate blade pitch switch.
Cause

Defective blade pitch switch

short circuit)
P03 (male)
Blade pitch switch

OFF (Released)
ON (Pressed)
Resistance between
15
Max. 1
Min. 1 M
Resistance between
12
Min. 1 M
Max. 1

Wiring harness between TMCN2 (female) E

Resistance Max. 1
P03 (female) 5
Resistance Max. 1
P03 (female) 2
Resistance Max. 1
@ P03 (female) 1
Possible causes
and standard valTMCN2 (female) E P03 (female) 5 with
chassis ground
TMCN2 (female) 5 P03 (female) 2 with
chassis ground
Resistance Min. 1 M
Resistance Min. 1 M

TMCN2 (female) E P03 (female) 5 with
chassis ground
Voltage
Max. 1 V

TMCN2 (female) 5 P03 (female) 2 with
chassis ground
Voltage
Max. 1 V
20-478
1
(5)
TMCN1, TMCN2
Blade pitch switch

OFF (Released)
ON (Pressed)

E TMCN1 4, @
Max. 1 V
5 11 V

5 TMCN1 4, @
5 11 V
Max. 1 V
D375A-5
TROUBLESHOOTING

SWITCH SYSTEMS)
Circuit diagram related to blade tilt switch and blade pitch switch
D375A-5
20-479
1
SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT

SWITCH SYSTEMS)
TROUBLESHOOTING
SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT SWITCH

SYSTEMS)
User code
Service code
E02
E0312
Trouble
Disconnection or short circuit in blade tilt switch systems

Contents of trouble Signals of both blade tilt switch circuit systems are turned ON or OFF simultaneously.

Assumes that switch is at SINGLE position.
Blade dual tilt mechanism does not work (When dual tilt operation is performed, single tilt mechanism
Problem that
appears on machine
works).
Inputting from blade tilt switch (ONOFF) can be checked in monitoring mode.
Related information
(Code bD: Blade lever knob switch input)
Method of reproducing service code: Turn starting switch ON and operate blade tilt switch.
Cause

Defective blade tilt switch

short circuit)
P03 (male)
Blade tilt switch

SINGLE
DUAL
Resistance between
36
Max. 1
Min. 1 M
Resistance between
34
Min. 1 M
Max. 1

Wiring harness between TMCN2 (female) Y

Resistance Max. 1
P03 (female) 6
Wiring harness between TMCN2 (female) O
Resistance Max. 1
P03 (female) 4
Resistance Max. 1
@ P03 (female) 3
Possible causes
and standard valTMCN2 (female) Y P03 (female) 6 with
chassis ground
TMCN2 (female) O P03 (female) 4 with
chassis ground
Resistance Min. 1 M
Resistance Min. 1 M

TMCN2 (female) Y P03 (female) 6 with
chassis ground
Voltage
Max. 1 V

TMCN2 (female) O P03 (female) 4 with
chassis ground
Voltage
Max. 1 V
troller
20-480
1
(5)
TMCN1, TMCN2
Blade tilt switch

SINGLE
DUAL

Y TMCN1 4, @
Max. 1 V
5 11 V

O TMCN1 4, @
5 11 V
Max. 1 V
D375A-5
TROUBLESHOOTING
SERVICE CODE E0312 (DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT

SWITCH SYSTEMS)
Circuit diagram related to blade tilt switch and blade pitch switch
D375A-5
20-481
1
TROUBLESHOOTING
SERVICE CODE E0321 (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID

SYSTEM)
SERVICE CODE E0321 (DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID

SYSTEM)
User code
Service code
E01
E0321
Trouble
Disconnection in blade dual selector solenoid system

Contents of trouble When signal is output to blade dual selector solenoid circuit, current does not flow.
Action of controller Stops outputting to blade dual selector solenoid circuit.

Problem that
appears on machine
works).
Related information
Outputting to blade dual selector solenoid (Voltage) can be checked in monitoring mode.
(Code d4: Blade dual solenoid drive voltage)
Method of reproducing service code: Turn starting switch ON and perform blade dual tilt operation.
Cause
Defective blade dual selector
1 solenoid

SOL2 (male)
Resistance
Between 1 2
10 40

ness
Wiring harness between TMCN3 (female) G
Resistance Max. 1
SOL2 (female) 1
Wiring harness between SOL (female) 2
tor)
chassis ground
ue in normal state
TMCN3 (female) G SOL2 (female) 1 with
Voltage Max. 1 V
chassis ground
TMCN3 (female)
Resistance
troller
Between G chassis ground
10 40
Circuit diagram related to blade dual selector solenoid
20-482
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0322 (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID

SYSTEM)
SERVICE CODE E0322 (SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID

SYSTEM)
User code
Service code
E01
E0322
Trouble
Short circuit in blade dual selector solenoid system

Contents of trouble When signal was output to blade dual selector solenoid circuit, abnormal current flowed.
Action of controller Stops outputting to blade dual selector solenoid circuit.

Problem that
appears on machine
works).
Related information
Outputting to blade dual selector solenoid (Voltage) can be checked in monitoring mode.
(Code d4: Blade dual solenoid drive voltage)
Method of reproducing service code: Turn starting switch ON and perform blade dual tilt operation.
Cause
Defective blade dual selector
1 solenoid

SOL2 (male)
Resistance
Between 1 2
10 40

Min. 1 M
Possible causes
(Contact with ground circuit) TMCN3 (female) G SOL2 (female) 1 with Resistance Min. 1 M
chassis ground
troller

TMCN3 (female)
Resistance
Between G chassis ground
10 40
Circuit diagram related to blade dual selector solenoid
D375A-5
20-483
1
TROUBLESHOOTING
SERVICE CODE E0323 (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID

SYSTEM)
SERVICE CODE E0323 (DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID

SYSTEM)
User code
Service code
E02
E0323
Trouble
Disconnection in blade pitch selector solenoid system

Contents of trouble When signal is output to blade pitch selector solenoid circuit, current does not flow.

Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on machine
Related information
Outputting to blade pitch selector solenoid (Voltage) can be checked in monitoring mode.
(Code d3: Blade pitch solenoid drive voltage)
Method of reproducing service code: Turn starting switch ON and perform blade pitch operation.
Cause

Defective blade pitch selecwithout turning starting switch ON.
1 tor solenoid
Resistance
SOL1 (male)
Between 1 2
10 40
ness
Wiring harness between TMCN3 (female) [
Resistance Max. 1
SOL1 (female) 1
Wiring harness between SOL1 (female) 2
tor)
chassis ground
ue in normal state
TMCN3 (female) [ SOL1 (female) 1 with
Voltage Max. 1 V
chassis ground
TMCN3 (female)
Resistance
troller
Between [ chassis ground
10 40
Circuit diagram related to blade pitch selector solenoid
20-484
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0324 (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID

SYSTEM)
SERVICE CODE E0324 (SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID

SYSTEM)
User code
Service code
E02
E0324
Trouble
Short circuit in blade pitch selector solenoid system

Contents of trouble When signal was output to blade pitch selector solenoid circuit, abnormal current flowed.

Stops outputting to blade pitch selector solenoid circuit.
Problem that
appears on machine
Related information
Outputting to blade pitch selector solenoid (Voltage) can be checked in monitoring mode.
(Code d3: Blade pitch solenoid drive voltage)
Method of reproducing service code: Turn starting switch ON and perform blade pitch operation.
Cause
Defective blade pitch selec1 tor solenoid

SOL1 (male)
Resistance
Between 1 2
10 40

Min. 1 M
Possible causes
(Contact with ground circuit) TMCN3 (female) [ SOL1 (female) 1 with Resistance Min. 1 M
chassis ground
troller
TMCN3 (female)
Resistance
Between [ chassis ground
10 40
Circuit diagram related to blade pitch selector solenoid
D375A-5
20-485
1
TROUBLESHOOTING
SERVICE CODE E0329 (ABNORMAL HYDRAULIC OIL TEMPERATURE)
SERVICE CODE E0329 (ABNORMAL HYDRAULIC OIL TEMPERATURE)

User code
Service code
E01
E0329
Trouble
Hydraulic oil temperature sensor: Out of input signal range
Contents of trouble The signal from the hydraulic oil temperature sensor is out of the normal range.
Action of controller None in particular.

Problem that
The hydraulic oil thermometer of the monitor panel may not be displayed normally.
appears on machine
Related information Method of reproducing error code: Turn the starting switch ON or start the engine.
Cause
Defective hydraulic oil tem- Prepare with starting switch OFF, then carry out troubleshooting
without turning starting switch.
perature sensor
1
Resistance
452 (male)
short circuit)
Between (1) and chassis ground
Min. 1 M
Possible causes
ness
2 (Disconnection in wiring harness or defective contact in Wiring harness between CN1 (female) (8) and Resistance Max. 1
452 (female) (1)
connector)
Between
CN1 (female) (8) 452 (female) (1)
Resistance Min. 1 M
wiring harness and chassis ground
(Contact with 24-V circuit)
Between CN1 (female) (8) 452 (female) (1)
wiring harness and chassis ground
Voltage
Max. 1 V
Circuit diagram related to hydraulic oil temperature sensor
20-485-1
(6)
D375A-5
TROUBLESHOOTING
SERVICE CODE E0364 (DISCONNECTION IN FRONT LARGE PUMP OIL PRESSURE

SENSOR SYSTEM)
SERVICE CODE E0364 (DISCONNECTION IN FRONT LARGE PUMP OIL PRESSURE

SENSOR SYSTEM)
User code
Service code
E0364
Trouble
Disconnection in front large pump oil pressure sensor system

Contents of trouble Signal voltage of front large pump oil pressure sensor circuit is below 0.5 V.
Action of controller Does not take any particular action.

Problem that
Oil pressure of front large pump cannot be monitored.
appears on machine
Related information
Outputting from front large pump oil pressure sensor (Voltage) can be checked in monitoring mode.
(Code 4L: Voltage of front large pump oil pressure sensor)
Cause
1
supply system
Defective front large pump
2 oil pressure sensor
(Internal trouble)
LPP
Between C A
Voltage
0.5 6.0 V

ness
Wiring harness between TMCN1 (female) F
Resistance Max. 1
Possible causes
LPP (female) B
and standard valdefective contact in connecWiring harness between TMCN1 (female) 9
ue in normal state
tor)
Resistance Max. 1
LPP (female) C
(Contact with ground circuit) TMCN1 (female) 9 LPP (female) C with
Resistance Min. 1 M
chassis ground
TMCN1
Voltage
troller
Between 9 K
0.5 6.0 V
Circuit diagram related to front large pump oil pressure sensor
20-486
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0365 (SHORT CIRCUIT IN FRONT LARGE PUMP OIL PRESSURE
SENSOR SYSTEM)
SERVICE CODE E0365 (SHORT CIRCUIT IN FRONT LARGE PUMP OIL PRESSURE
SENSOR SYSTEM)
User code
Service code
E0365
Trouble
Short circuit in front large pump oil pressure sensor system

Contents of trouble Signal voltage of front large pump oil pressure sensor circuit is above 6.0 V.

Problem that
Oil pressure of front large pump cannot be monitored.
appears on machine
Outputting from work equipment large pump oil pressure sensor (Voltage) can be checked in monitoring mode.
Related information
(Code 4L: Voltage of front large pump oil pressure sensor)
Cause
1
supply system
Defective front large pump
(Internal trouble)
Possible causes


troller
LPP
Between C A
Voltage
0.5 6.0 V
TMCN1 (female) 9 LPP (female) C with
chassis ground
Voltage
Max. 1 V
TMCN1
Voltage
Between 9 K
0.5 6.0 V
Circuit diagram related to front large pump oil pressure sensor
D375A-5
20-487
1
TROUBLESHOOTING
SERVICE CODE E0366 (DISCONNECTION IN CENTER SMALL PUMP OIL PRESSURE

SENSOR SYSTEM)
SERVICE CODE E0366 (DISCONNECTION IN CENTER SMALL PUMP OIL PRESSURE

SENSOR SYSTEM)
User code
Service code
E0366
Trouble
Disconnection in center small pump oil pressure sensor system

Contents of trouble Signal voltage of center small pump oil pressure sensor circuit is below 0.5 V.

Problem that
Oil pressure of center small pump cannot be monitored.
appears on machine
Related information
Outputting from center small pump oil pressure sensor (Voltage) can be checked in monitoring mode.
(Code 45: Voltage of center small pump oil pressure sensor)
Cause
1
supply system
Defective center small pump
(Internal trouble)
SPP
Between C A
Voltage
0.5 6.0 V

ness
Wiring harness between TMCN1 (female) F
Resistance Max. 1
Possible causes
SPP (female) B
and standard valdefective contact in connecWiring harness between TMCN1 (female) 3
ue in normal state
tor)
Resistance Max. 1
SPP (female) C
(Contact with ground circuit) TMCN1 (female) 3 SPP (female) C with
Resistance Min. 1 M
chassis ground
TMCN1
Voltage
troller
Between 3 K
0.5 6.0 V
Circuit diagram related to center small pump oil pressure sensor
20-488
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0367 (SHORT CIRCUIT IN CENTER SMALL PUMP OIL PRESSURE
SENSOR SYSTEM)
SERVICE CODE E0367 (SHORT CIRCUIT IN CENTER SMALL PUMP OIL PRESSURE
SENSOR SYSTEM)
User code
Service code
E0367
Trouble
Short circuit in center small pump oil pressure sensor system

Contents of trouble Signal voltage of center small pump oil pressure sensor circuit is above 6.0 V.

Problem that
Oil pressure of center small pump cannot be monitored.
appears on machine
Related information
Outputting from center small pump oil pressure sensor (Voltage) can be checked in monitoring mode.
(Code 45: Voltage of center small pump oil pressure sensor)
Cause
1
supply system
Defective center small pump
(Internal trouble)
Possible causes

SPP
Between C A
Voltage
0.5 6.0 V
TMCN1 (female) 3 SPP (female) C with
chassis ground
Voltage
Max. 1 V
troller
TMCN1
Voltage
Between 3 K
0.5 6.0 V
Circuit diagram related to center small pump oil pressure sensor
D375A-5
20-489
1
TROUBLESHOOTING
SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL

DIAL SYSTEM)
SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL DIAL

SYSTEM)
User code
Service code
CALL03
E0405
Trouble
Disconnection or short circuit in fuel control dial system

Contents of trouble Signal voltage of fuel control dial circuit is below 0.30 V or above 4.55 V.

Action of controller Continues controlling with signal of decelerator pedal potentiometer.
Problem that
Related information
Inputting from fuel control dial (Voltage) can be checked in monitoring mode.
(Code F6: Voltage of fuel control dial)
Cause
1
supply system
Defective fuel control dial
short circuit)
TL1 (male)
Resistance
Between R S
0.25 7.0 k
Between R T
Between S T
4.0 6.0 k
0.25 7.0 k

ness
Wiring harness between NGICN1 (female) L
Resistance Max. 1
TL1 (female) R
Possible causes
defective contact in connecWiring harness between NGICN1 (female) 8
and standard valtor)
Resistance Max. 1
TL1 (female) S
ue in normal state
(Contact with ground circuit) NGICN1 (female) 8 TL1 (female) S with Resistance Min. 1 M
chassis ground
NGICN1 (female) 8 TL1 (female) S
Voltage
Max. 1 V
NGICN1
Voltage
troller
Between 8 K
20-490
1
0.30 4.33 V
D375A-5
TROUBLESHOOTING
SERVICE CODE E0405 (DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL

DIAL SYSTEM)
Circuit diagram related to fuel control dial
D375A-5
20-491
1
SERVICE CODE E0430 (ENGINE OIL: ABNORMAL OIL PRESSURE)

SERVICE CODE E0431 (ABNORMAL RADIATOR COOLANT LEVEL)
SERVICE CODE E0432 (RADIATOR COOLANT: OVERHEATING)
TROUBLESHOOTING
SERVICE CODE E0430 (ENGINE OIL: ABNORMAL OIL PRESSURE)

User code
Service code
CALL
E0430
Trouble
Engine oil: Abnormal oil pressure
Contents of trouble While the engine is running, the engine oil pressure caution lamp flashes.
Action of controller Sounds the caution buzzer (Function of monitor panel).

Problem that
If the machine is operated as it is, the engine may be damaged.
appears on machine
Related information Method of reproducing error code: Start the engine.
Cause
Possible causes
Standard value in normal state/Remarks on troubleshooting.
Lowering of engine oil presA phenomenon seems to have caused lowering of the engine oil pres1 sure
sure. Find and stop it and repair the damaged part.
2
Defective engine oil pressure caution lamp system
Carry out troubleshooting for the engine oil pressure caution lamp
system according to "E-8 While engine is running, emergency stop
item flashes" in E-mode.
SERVICE CODE E0431 (ABNORMAL RADIATOR COOLANT LEVEL)

User code
Service code
CALL
E0431
Trouble
Abnormal radiator coolant level
Contents of trouble When the starting switch is turned ON, the radiator coolant level caution lamp flashes.
Problem that
appears on machine
Related information Method of reproducing error code: Turn the starting switch ON.
Cause
Possible causes
Lowering of radiator coolant

A phenomenon seems to have caused lowering of the radiator coolant
1 level
level. Find and stop it and repair the damaged part.
2
Defective radiator coolant

level caution lamp system
Carry out troubleshooting for the radiator coolant level caution lamp
system according to "E-6 When starting switch is turned ON, basic
item flashes" in E-mode.
SERVICE CODE E0432 (RADIATOR COOLANT: OVERHEATING)

User code
Service code
E01
E0432
Trouble
Radiator coolant: Overheating
Contents of trouble While the engine is running, the engine coolant temperature caution lamp flashes.
Action of controller Sounds the caution buzzer (Function of monitor panel).

Problem that
appears on machine
Related information Method of reproducing error code: Start the engine.
Cause
Possible causes
20-491-1
(6)
Overheating of engine coolA phenomenon seems to have caused overheating of the engine cool1 ant
ant. Find and stop it and repair the damaged part.
Defective engine coolant
2 temperature caution lamp
system
Carry out troubleshooting for the engine coolant temperature caution

lamp system according to "E-8 While engine is running, emergency
stop item flashes" in E-mode.
D375A-5
SERVICE CODE E0486 (ABNORMALITY IN SELECTION OF TRANSMISSION

TROUBLESHOOTING
SERVICE CODE E0486 (ABNORMALITY IN SELECTION OF TRANSMISSION

User code
Service code
CALL
E0486
Contents of trouble
Trouble
Abnormality in selection of transmission controller specification

Internal setting of transmission controller specification is different from specification setting signal
(Transmission controller cannot recognize specification setting normally).

Action of controller Stops transmission controller from outputting all signals.
Machine does not move at all.
Problem that
appears on machine
Cause
Defective adjustment of
transmission controller
After adjustment mode is executed, if service code changes to P (to

indicate that trouble is repaired), system is normal.
Adjustment code 7A: Check of specification code
(Transmission controller)
Possible causes
and standard val- 2 ness
(Disconnection
in
wiring
or
deue in normal state
Wiring harness between TMCN3 (female) @
Resistance Max. 1
fective contact in connector) chassis ground
TMCN3
Voltage
troller
Between @ chassis ground
Max. 1 V
Circuit diagram related to transmission controller specification selection signal
20-492
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0501 (DISCONNECTION OR SHORT CIRCUIT IN ACCELERATION

SENSOR SYSTEM)
SERVICE CODE E0501 (DISCONNECTION OR SHORT CIRCUIT IN ACCELERATION

SENSOR SYSTEM)
User code
Service code
E01
E0501
Trouble
Disconnection or short circuit in acceleration sensor system

Contents of trouble Signal voltage of acceleration sensor is below 0.3 V or above 4.7 V.
Action of controller Stops shoe slip control (SSC) function.

Problem that
Even if shoe slips, engine speed does not change.
appears on machine
Related information
Inputting from acceleration sensor (Voltage) can be checked in monitoring mode.

(Code A5: Voltage of acceleration sensor)
Cause
1
supply system
Defective acceleration sen2 sor
(Internal trouble)
Possible causes
SS3
Voltage
Between 2 3
0.75 4.25 V

ness
Resistance Max. 1
SS3 (female) 1
tor)
Resistance Max. 1
SS3 (female) 2
(Contact with ground circuit) NGICN1 (female) 1 SS3 (female) 2 with Resistance Min. 1 M
chassis ground

troller
NGICN1 (female) 1 SS3 (female) 2
Voltage
Max. 1 V
NGICN1
Voltage
Between 1 K
0.75 4.25 V
Circuit diagram related to acceleration sensor
D375A-5
20-493
1
TROUBLESHOOTING
SERVICE CODE E0610 (DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)

User code
Service code
E01
E0610
Trouble
Disconnection in back-up alarm relay system

Contents of trouble When GND signal for back-up alarm relay circuit is turned off, 24 V is not generated.
Action of controller Stops outputting to back-up alarm relay circuit.

Problem that
Back-up alarm does not sound.
appears on machine
Outputting to back-up alarm relay (Voltage) can be checked in monitoring mode.

(Code db: Back-up alarm relay drive voltage)
Related information Method of reproducing service code: Turn starting switch ON and set parking brake lever in neutral.
This service code detects abnormality on primary side (coil side) of back-up alarm relay and cannot
Cause
1 Defective fuse FS4-1
Defective back-up alarm re2 lay
Possible causes

If fuse is broken, circuit probably has short circuit with chassis ground.
BKA (male)
Resistance
Between 1 2
200 400

ness
Wiring harness between TMCN2 (female) H
Resistance Max. 1
BKA (female) 2
defective contact in connecWiring harness between BKA (female) 1
tor)
Resistance Max. 1
FS4-1 outlet
TMCN2 (female) H BKA (female) 2 with
(Contact with ground circuit) chassis ground
Resistance Min. 1 M
Short circuit of wiring harness between BKA

Resistance Min. 1 M
(female) 1 FS4-1 outlet with chassis ground
5
20-494
1
(5)
TMCN2
PCCS lever
Voltage
Between H chassis
ground
Neutral
20 30 V
Reverse
Max. 1 V
D375A-5
TROUBLESHOOTING
Circuit diagram related to back-up alarm
D375A-5
20-495
1
TROUBLESHOOTING
SERVICE CODE E0611 (SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)

User code
Service code
E01
E0611
Trouble
Short circuit in back-up alarm relay system

Contents of trouble When GND signal for back-up alarm relay circuit was output, abnormal current flowed.
Action of controller Stops outputting to back-up alarm relay circuit.

Problem that
Back-up alarm does not sound.
appears on machine
Outputting to back-up alarm relay (Voltage) can be checked in monitoring mode.

(Code db: Back-up alarm relay drive voltage)
Related information Method of reproducing service code: Turn starting switch ON and operate PCCS lever (in reverse).
This service code detects abnormality on primary side (coil side) of back-up alarm relay and cannot
Cause
Defective back-up alarm re1 lay
Possible causes
ue in normal state

BKA (male)
Resistance
Between 1 2
200 400
TMCN2 (female) H BKA (female) 2
Voltage
Max. 1 V
3
20-496
1
(5)
TMCN2
PCCS lever
Voltage
Between H chassis
ground
Neutral
20 30 V
Reverse
Max. 1 V
D375A-5
TROUBLESHOOTING
D375A-5
20-497
1
TROUBLESHOOTING
SERVICE CODE E0660 (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM)
SERVICE CODE E0660 (DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM)

User code
Service code
E0660
Trouble
Disconnection in ACC signal drive relay system

Contents of trouble When signal is output to ACC signal drive circuit, current does not flow.
Action of controller Stops outputting to ACC signal drive relay circuit.

Problem that
Turbocharger timer function does not work (if equipped).
appears on machine
Outputting to ACC signal drive relay (Voltage) can be checked in monitoring mode.
(Code d8: Engine controller relay drive voltage)
Related information
Turn starting switch ON and OFF (when turbocharger timer is in operation).
This service code detects abnormality on primary side (coil side) of ACC signal drive relay and cannot
Cause
Defective ACC signal drive
1 relay

SDR (male)
Resistance
Between 1 2
200 400

ness
Wiring harness between NGICN3 (female) H
Resistance Max. 1
SDR (female) 1
Possible causes
defective contact in connecand standard valWiring harness between SDR (female) 2
tor)
Resistance Max. 1
ue in normal state
chassis ground
NGICN3 (female) H SDR (female) 1
Voltage
Max. 1 V

Resistance
SGICN3 (female)
troller
Between H chassis ground
200 400
Circuit diagram related to ACC signal drive relay
20-498
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0661 (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM)
SERVICE CODE E0661 (SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM)
User code
Service code
E0661
Trouble
Short circuit in ACC signal drive relay system

Contents of trouble When signal is output to ACC signal drive circuit, abnormal current flowed.
Action of controller Stops outputting to ACC signal drive relay circuit.

Problem that
Turbocharger timer function does not work (if equipped).
appears on machine
Outputting to ACC signal drive relay (Voltage) can be checked in monitoring mode.
(Code d8: Engine controller relay drive voltage)
Related information
Turn starting switch ON and OFF (when turbocharger timer is in operation).
This service code detects abnormality on primary side (coil side) of ACC signal drive relay and cannot
Cause
Defective ACC signal drive
1 relay

SDR (male)
Resistance
Between 1 2
200 400

Possible causes
Short
circuit
with
chassis
and standard val2
ground
in
wiring
harness
Short
circuit of wiring harness between
ue in normal state
(Contact with ground circuit) NGICN3 (female) H SDR (male) 1 with
Resistance Min. 1 M
chassis ground
troller

TMCN3 (female)
Resistance
Between H chassis ground
200 400
Circuit diagram related to ACC signal drive relay
D375A-5
20-499
1
TROUBLESHOOTING

SENSOR SYSTEM)

SENSOR SYSTEM)
User code
Service code
CALL03
E0721
Trouble
Disconnection or short circuit in pitch angle sensor system

Contents of trouble Signal voltage of pitch angle sensor circuit is below 0.15 V or above 4.85 V.

Steering function and braking function may lower.
Problem that
appears on machine
Since pitch angle sensor signal is input to both steering controller and transmission controller, related
Related information
Inputting from pitch angle revolution sensor (Voltage) can be checked in monitoring mode.
(Code A8: Pitch angle sensor voltage)
Cause

Possible causes

1
(Disconnection in wiring or de- Wiring harness between NGICN2 (female) C
Resistance Max. 1
fective contact in connector) circuit branching point
NGICN2
Resistance
troller
Between C chassis ground
0.15 4.85 V

Cause
1
supply system
Defective pitch angle sensor
2
(Internal trouble)
Possible causes
PAS
Between B A
Voltage
0.15 4.85 V


Wiring harness between PAS (female) B
3
(Disconnection in wiring or de- circuit branching point
fective contact in connector) Wiring harness between PAS (male) C
NGICN1 (female) F
Resistance Max. 1
Resistance Max. 1

Short circuit of wiring harness between PAS
(Contact with ground circuit) (female) B TMCN1 (female) C NGICN1 Resistance Min. 1 M
(female) C with chassis ground
20-500
1
D375A-5
TROUBLESHOOTING

SENSOR SYSTEM)
Circuit diagram related to pitch angle sensor
D375A-5
20-501
1
SERVICE
CODECODE
E0730 E0730
[ABNORMALITY
IN BOTH STEERING
POTENTIOMETER
SYSTEMS (1)]
SERVICE
[ABNORMALITY
IN BOTH STEERING
POTENTIOMETER
SYSTEMS(1)]
(2)]
TROUBLESHOOTING SERVICE CODE E0731 [ABNORMALITY IN BOTH STEERING POTENTIOMETER
SYSTEMS
SERVICE CODE E0730 [ABNORMALITY IN BOTH STEERING POTENTIOMETER

SYSTEMS (1)]
User code
Service code
CALL
E0730
Contents of trouble
Trouble
Abnormality in both steering potentiometer systems (1)

Service codes [E0733] and [E0734] are displayed simultaneously for steering potentiometer systems
1 and 2.

Problem that
Inputting from steering potentiometers (Voltage) can be checked in monitoring mode.
(Code L1: Voltage of steering potentiometer 1)
Related information
Method of reproducing service code: Turn starting switch ON and operate PCCS lever (Steering).
Possible causes
Cause

SYSTEMS (2)]
User code
Service code
CALL
E0731
Trouble

Steering potentiometer systems 1 and 2 are normal when starting switch is turned ON, then service
Contents of trouble
code [E0735] is displayed.


Problem that
Related information
Possible causes
20-502
1
Cause
D375A-5
TROUBLESHOOTING

SYSTEMS (3)]

SYSTEMS (3)]
User code
Service code
CALL
E0732
Contents of trouble
Trouble

Either of steering potentiometers 1 and 2 is abnormal when starting switch is turned ON, then service
codes [E0733] and [E0734] are displayed simultaneously.

Problem that
Related information
Possible causes
D375A-5
Cause
20-503
1
SERVICE CODE E0733 (DISCONNECTION OR SHORT CIRCUIT IN STEERING

TROUBLESHOOTING

User code
Service code
CALL03
E0733
Trouble
Disconnection or short circuit in steering potentiometer 1 system

Contents of trouble Signal voltage of steering potentiometer 1 (ST1) is below 0.5 V or above 4.5 V.

Action of controller Continues controlling with signal of steering potentiometer 2 system (ST2).
Problem that
Related information
Inputting from steering potentiometer 1 (ST1) (Voltage) can be checked in monitoring mode.
Cause
1
supply system
Defective steering potentiometer 1
2
short circuit)
Possible causes
Between A G
Between H A
Resistance
2 k 20%
Between H G

(Contact with ground circuit) NGICN1 (female) 2 TL1 (female) H with Resistance Min. 1 M
chassis ground
TL1 (male)

ness
Resistance Max. 1
TL1 (female) A
tor)
Resistance Max. 1
TL1 (female) H

20-504

NGICN1 (female) 2 TL1 (female) H with
chassis ground
Voltage
Max. 1 V
NGICN1
Voltage
Between 2 K
0.5 4.5 V
D375A-5
TROUBLESHOOTING

Circuit diagram related to steering potentiometer
D375A-5
20-505
1

TROUBLESHOOTING

User code
Service code
CALL03
E0734
Trouble
Disconnection or short circuit in steering potentiometer 2 system

Contents of trouble Signal voltage of steering potentiometer 2 (ST2) is below 0.5 V or above 4.5 V.

Action of controller Continues controlling with signal of steering potentiometer 1 system (ST1).
Problem that
Related information
Inputting from steering potentiometer 2 (ST2) (Voltage) can be checked in monitoring mode.
Cause
Defective sensor power sup- See if service code [E0143] is displayed. If it is displayed, carry out
1
ply system
Defective steering potentiometer 2
2
short circuit)
Possible causes
Between M F
Between E M
Resistance
2 k 20%
Between E F

(Contact with ground circuit) NGICN1 (female) I TL1 (female) E with Resistance Min. 1 M
chassis ground
TL1 (male)

ness
Resistance Max. 1
TL1 (female) M
defective contact in connecWiring harness between NGICN1 (female) I
tor)
Resistance Max. 1
TL1 (female) E

20-506

NGICN1 (female) I TL1 (female) E with
chassis ground
Voltage
Max. 1 V
NGICN1
Voltage
Between I K
0.5 4.5 V
D375A-5
SERVICE CODE E0735 (DEVIATION OF STEERING POTENTIOMETER SYSTEM

SIGNALS)
TROUBLESHOOTING
Circuit diagram related to steering potentiometers
SERVICE CODE E0735 (DEVIATION OF STEERING POTENTIOMETER SYSTEM

SIGNALS)
User code
Service code
CALL03
E0735
Trouble
Deviation of steering potentiometer system signals

Contents of trouble Total signal voltages of steering potentiometers 1 (ST1) and 2 (ST2) is below 4.41 V or above 5.59 V.

Action of controller Continues controlling with normal signal of steering potentiometer 1 (ST1) system or 2 (ST2) system.
Problem that
Possible causes
D375A-5
Cause
20-507
1
SERVICE CODE E0736 (DISCONNECTION OR SHORT CIRCUIT IN BRAKE

POTENTIOMETER SYSTEM)
TROUBLESHOOTING

User code
Service code
CALL03
E0736
Trouble
Disconnection or short circuit in brake potentiometer system

Contents of trouble Signal voltage of brake potentiometer circuit is below 0.5 V or above 4.5 V.

Action of controller Stops controlling with brake potentiometer signal.
Brake control performance of brake pedal lowers.
Problem that
appears on machine
Related information
Inputting from brake potentiometer (Voltage) can be checked in monitoring mode.

(Code L7: Voltage of brake potentiometer)
Method of reproducing service code: Turn starting switch ON and operate brake pedal.
Cause
1
supply system
Defective brake potentiometer
2
short circuit)
Possible causes
Resistance
Between A B
0.25 7.0 k
Between A C
Between B C
4.0 6.0 k
0.25 7.0 k

(Contact with ground circuit) NGICN1 (female) 3 BRK (female) B with Resistance Min. 1 M
chassis ground
BRK (male)

ness
Resistance
BRK (female) C
tor)
Resistance
BRK (female) B

20-508

NGICN1 (female) 3 BRK (female) B with
chassis ground
Voltage
Max. 1 V
NGICN1
Between 3 B
Voltage
0.5 4.5 V
D375A-5
TROUBLESHOOTING

Circuit diagram related to brake potentiometer
D375A-5
20-509
1
TROUBLESHOOTING
SERVICE CODE E0750 (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV

SYSTEM)
SERVICE CODE E0750 (DISCONNECTION IN RIGHT STEERING CLUTCH ECMV SYSTEM)

User code
Service code
CALL03
E0750
Trouble
Disconnection in right steering clutch ECMV system

Contents of trouble When signal is output to right steering clutch solenoid circuit, current does not flow.

Action of controller Stops outputting to right steering clutch solenoid circuit.
Machine cannot be steered to right.
Problem that
appears on machine
Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
(Code P4, c4: Right steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).
Cause
Defective right steering
1 clutch solenoid
Possible causes

SRC (male)
Resistance
Between 1 2
5 15

ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) Y Resistance Max. 1
SRC (female) 1
defective contact in connecWiring harness between NGICN3 (female) M
tor)
Resistance Max. 1
SRC (female) 2
aPrepare with starting switch OFF, then turn starting switch ON and
NGICN3 (female) Y SRC (female) 1 with
chassis ground
Voltage
Max. 1 V

NGICN3 (female)
Resistance
Between Y M
5 15
Circuit diagram related to right steering clutch ECMV
20-510
(7)
1
D375A-5
SERVICE CODE E0751 (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0751 (SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV SYSTEM)
User code
Service code
CALL03
E0751
Trouble
Short circuit in right steering clutch ECMV system

Contents of trouble When signal was output to right steering clutch solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to right steering clutch solenoid circuit.
Machine cannot be steered to right.
Problem that
appears on machine
Outputting to right steering clutch solenoid (Current) can be checked in monitoring mode.
(Code P4, c4: Right steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to right).
Cause
1 clutch solenoid
Possible causes

SRC (male)
Resistance
Between 1 2
5 15
Min. 1 M

(Contact with ground circuit) NGICN3 (female) Y SRC (female) 1 with Resistance Min. 1 M
chassis ground
3

NGICN3 (female) Y SRC (female) 1 with
Resistance Min. 1 M
wiring harness between NGICN3 (female) M
SRC (female) 2
NGICN3 (female)
Resistance
Between Y M
5 15
Between Y chassis ground
Min. 1 M
Circuit diagram related to right steering clutch ECMV
D375A-5
20-511
(7)
1
SERVICE CODE E0752 (DISCONNECTION IN LEFT STEERING CLUTCH ECMV

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0752 (DISCONNECTION IN LEFT STEERING CLUTCH ECMV SYSTEM)

User code
Service code
CALL03
E0752
Trouble
Disconnection in left steering clutch ECMV system

Contents of trouble When signal is output to left steering clutch solenoid circuit, current does not flow.

Action of controller Stops outputting to left steering clutch solenoid circuit.
Machine cannot be steered to left.
Problem that
appears on machine
Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
(Code P3, c3: Left steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).
Cause
Defective left steering clutch
1 solenoid
Possible causes

SLC (male)
Resistance
Between 1 2
5 15

ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) O Resistance Max. 1
SLC (female) 1
defective contact in connecWiring harness between NGICN3 (female) M
tor)
Resistance Max. 1
SLC (female) 2
NGICN3 (female) O SLC (female) 1 with
chassis ground
Voltage
Max. 1 V

NGICN3 (female)
Resistance
Between O M
5 15
Circuit diagram related to left steering clutch ECMV
20-512
(7)
1
D375A-5
SERVICE CODE E0753 (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0753 (SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV SYSTEM)
User code
Service code
CALL03
E0753
Trouble
Short circuit in left steering clutch ECMV system

Contents of trouble When signal was output to left steering clutch solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to left steering clutch solenoid circuit.
Machine cannot be steered to left.
Problem that
appears on machine
Outputting to left steering clutch solenoid (Current) can be checked in monitoring mode.
(Code P3, c3: Left steering clutch ECMV output current)
Related information
Turn starting switch ON, release parking brake, and operate PCCS lever (to steer to left).
Cause
Defective left steering clutch
1 solenoid
Possible causes

SLC (male)
Resistance
Between 1 2
5 15
Min. 1 M

(Contact with ground circuit) NGICN3 (female) O SLC (female) 1 with Resistance Min. 1 M
chassis ground
3

NGICN3 (female) O SLC (female) 1 with
Resistance Min. 1 M
wiring harness between NGICN3 (female) M
SLC (female) 2
NGICN3 (female)
Resistance
Between O M
5 15
Min. 1 M
Circuit diagram related to left steering clutch ECMV
D375A-5
20-513
(7)
1
SERVICE CODE E0754 (DISCONNECTION IN RIGHT STEERING BRAKE ECMV

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0754 (DISCONNECTION IN RIGHT STEERING BRAKE ECMV SYSTEM)

User code
Service code
CALL
E0754
Trouble
Disconnection in right steering brake ECMV system

Contents of trouble When signal is output to right steering brake solenoid circuit, current does not flow.

Action of controller Stops outputting to right steering brake solenoid circuit.
Brake is kept applied lightly during travel.
Problem that
appears on machine
Related information
Outputting to right steering brake solenoid (Current) can be checked in monitoring mode.
(Code P2, c2: Right steering brake ECMV output current)
Method of reproducing service code: Turn starting switch ON and release parking brake lever.
Cause
1 brake solenoid
Possible causes

SRB (male)
Resistance
Between 1 2
5 15

ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) E Resistance Max. 1
SRB (female) 1
defective contact in connecWiring harness between NGICN3 (female) C
tor)
Resistance Max. 1
SRB (female) 2
NGICN3 (female) E SRB (female) 1 with
chassis ground
Voltage
Max. 1 V

NGICN3 (female)
Resistance
Between E C
5 15
Circuit diagram related to right steering brake ECMV
20-514
(7)
1
D375A-5
SERVICE CODE E0755 (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0755 (SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV SYSTEM)
User code
Service code
CALL
E0755
Trouble
Short circuit in right steering brake ECMV system

Contents of trouble When signal was output to right steering brake solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to right steering brake solenoid circuit.
Limits operation of engine, transmission, brake.
Problem that
appears on machine
Related information
Outputting to right steering brake solenoid (Current) can be checked in monitoring mode.
(Code P2, c2: Right steering brake ECMV output current)
Cause
1 brake solenoid

SRB (male)
Resistance
Between 1 2
5 15
Min. 1 M

Possible causes

(Contact with ground circuit) NGICN3 (female) E SRB (female) 1 with
chassis ground
3
Resistance Min. 1 M

NGICN3 (female) E SRB (female) 1 with
Resistance Min. 1 M
wiring harness between NGICN3 (female) C
SRB (female) 2
NGICN3 (female)
Resistance
Between E C
5 15
Between E chassis ground
Min. 1 M
Circuit diagram related to right steering brake ECMV
D375A-5
20-515
(7)
1
SERVICE CODE E0756 (DISCONNECTION IN LEFT STEERING BRAKE ECMV

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0756 (DISCONNECTION IN LEFT STEERING BRAKE ECMV SYSTEM)

User code
Service code
CALL
E0756
Trouble
Disconnection in left steering brake ECMV system

Contents of trouble When signal is output to left steering brake solenoid circuit, current does not flow.

Action of controller Stops outputting to left steering brake solenoid circuit.
Problem that
appears on machine
Related information
Outputting to left steering brake solenoid (Current) can be checked in monitoring mode.
(Code P1, c1: Left steering brake ECMV output current)
Cause
Defective left steering brake
1 solenoid
Possible causes

SLB (male)
Resistance
Between 1 2
5 15

ness
2 (Disconnection in wiring or Wiring harness between NGICN3 (female) 5 Resistance Max. 1
SLB (female) 1
defective contact in connecWiring harness between NGICN3 (female) C
tor)
Resistance Max. 1
SLB (female) 2
NGICN3 (female) 5 SLB (female) 1 with
chassis ground
Voltage
Max. 1 V

NGICN3 (female)
Resistance
Between 5 C
5 15
Circuit diagram related to left steering brake ECMV
20-516
(7)
1
D375A-5
SERVICE CODE E0757 (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0757 (SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV SYSTEM)
User code
Service code
CALL
E0757
Trouble
Short circuit in left steering brake ECMV system

Contents of trouble When signal was output to left steering brake solenoid circuit, abnormal current flowed.

Action of controller Stops outputting to left steering brake solenoid circuit.
Problem that
appears on machine
Related information
Outputting to left steering brake solenoid (Current) can be checked in monitoring mode.
(Code P1, c1: Left steering brake ECMV output current)
Cause
Defective left steering brake
1 solenoid

SLB (male)
Resistance
Between 1 2
5 15
Min. 1 M

Possible causes

(Contact with ground circuit) NGICN3 (female) 5 SLB (female) 1 with
chassis ground
3
Resistance Min. 1 M

NGICN3 (female) 5 SLB (female) 1 with
Resistance Min. 1 M
SLB (female) 2
NGICN3 (female)
Resistance
Between 5 C
5 15
Min. 1 M
Circuit diagram related to left steering brake ECMV
D375A-5
20-517
(7)
1
SERVICE CODE E0779 (DISCONNECTION IN SUDDEN STOP PREVENTION

SOLENOID SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0779 (DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID

SYSTEM)
User code
Service code
CALL
E0779
Trouble
Disconnection in sudden stop prevention solenoid system

Contents of trouble When signal is output to sudden stop prevention solenoid circuit, current does not flow.

Problem that
appears on machine
Related information
Outputting to sudden stop prevention solenoid (Voltage) can be checked in monitoring mode.
(Code d5: Sudden stop prevention solenoid drive voltage)
Cause
Defective sudden stop pre1 vention solenoid

STB (male)
Resistance
Between 1 2
5 25

ness
Resistance Max. 1
STB (female) 1
Wiring harness between NGICN3 (female) C
tor)
STB (female) 2
ue in normal state
NGICN3 (female) 7 STB (female) 1 with
Voltage Max. 1 V
chassis ground
NGICN3 (female)
Resistance
Between 7 C
5 25
Circuit diagram related to sudden stop prevention solenoid
20-526
1
D375A-5
SERVICE CODE E0780 (SHORT CIRCUIT IN SUDDEN STOP PREVENTION

SOLENOID SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0780 (SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID

SYSTEM)
User code
Service code
CALL
E0780
Trouble
Short circuit in sudden stop prevention solenoid system

Contents of trouble When signal is output to sudden stop prevention solenoid circuit, abnormal current flowed.

Problem that
appears on machine
Related information
Outputting to sudden stop prevention solenoid (Voltage) can be checked in monitoring mode.
(Code d5: Sudden stop prevention solenoid drive voltage)
Cause
Defective sudden stop pre1 vention solenoid
Possible causes

STB (male)
Resistance
Between 1 2
5 25
Min. 1 M

(Contact with ground circuit) Short circuit of wiring harness between
Resistance Max. 1
NGICN3 (female) 7 STB (female) 1
3

NGICN3 (female) 7 STB (female) 1 with
Resistance Max. 1
STB (female) 2
NGICN3 (female)
Resistance
Between 7 C
5 25
Min. 1 M
Circuit diagram related to sudden stop prevention solenoid
D375A-5
20-527
1
TROUBLESHOOTING


User code
CALL03
Contents of trouble
Problem that
appears on machine
Related information
Service code
Disconnection or short circuit in parking brake lever switch systems
Trouble
E0781
Signals of both parking brake lever switch circuit systems are turned ON or OFF simultaneously.
Assumes that parking brake lever is at FREE position.
Travel lock does not work (Mechanical parking brake and pedal work normally.)
Since parking brake switch signal is used by both transmission controller and steering controller, related codes may be displayed simultaneously, depending on troubled part.
(Related codes: E0238, E0239, E0782)
(Code L9: Steering controller switch input 1)

Cause
ness
Resistance Max. 1
defective contact in connecWiring harness between NGICN2 (female) E
Resistance Max. 1
tor)
Possible causes
and standard valcarry out troubleshooting.
ue in normal state
Parking brake lever
NGICN2
At FREE
At LOCK
Between 5 chassis
Max. 1 V
5 11 V
ground
Between E chassis
5 11 V
Max. 1 V
ground
Possible causes
3
20-528
1
(5)

Cause
Defective parking brake leParking brake lever
ver switch
NSW
At FREE
At LOCK
Between A B
Max. 1
Min. 1 M
short circuit)
Between A C
Min. 1 M
Max. 1
Disconnection in wiring harWiring
harness between NSW (female) B
ness
Resistance Max. 1
circuit merging point
(Disconnection in wiring or
Wiring harness between NSW (female) C
Resistance Max. 1
defective contact in connec- circuit merging point
tor)
Wiring harness between NSW (female) A
Resistance Max. 1
chassis ground
Short
(female) B NGICN2 (female) 5 TMCN1 Resistance Min. 1 M
ground in wiring harness
(female) H with chassis ground
(female) C NGICN2 (female) E TMCN1 Resistance Min. 1 M
Short
(female) B NGICN2 (female) 5 TMCN1
Voltage Max. 1 V
source in wiring harness
(female) H with chassis ground
(female) C NGICN2 (female) E TMCN1
Voltage Max. 1 V
D375A-5
TROUBLESHOOTING

Circuit diagram related to parking brake switch
D375A-5
20-529
1
TROUBLESHOOTING

SYSTEM SIGNALS)

SYSTEM SIGNALS)
User code
Service code
CALL03
E0782
Contents of trouble
Trouble
Disagreement of parking brake lever switch system signals

Switch input signal of steering controller disagrees with communication signal from steering controller.

Problem that
Since parking brake switch signal is used by both transmission controller and steering controller and
information is exchanged by S-NET communication, related codes may be displayed simultaneously,
depending on troubled part.
Related information
(Related codes: E0101, E0104, E0105, E0152, E0164, E0238, E0239, E0781)
(Code L9: Steering controller switch input 1)
Cause
Possible causes
See if service codes [E0101], [E0104], [E0105], [E0152], and [E0162]

Defective S-NET communi1
are displayed. If they are displayed, carry out troubleshooting for them
cation system
first.
2
Defective parking brake lever switch signal system
displayed, carry out troubleshooting for them first.
(Service code [E0239] is same as [E0782].)
3 Defective steering controller Since trouble is in system, troubleshooting cannot be carried out.
20-530
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E0930 (DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)

User code
Service code
E01
E0930
Trouble

Contents of trouble Engine speed signal is not input from engine controller.
Action of controller Cannot recognize engine speed.

Tachometer graphic section is not displayed.
Problem that
appears on machine Steering performance may lower.
Since engine speed signal is input to both steering controller and transmission controller, related
Related information
Inputting from engine speed sensor (Voltage) can be checked in monitoring mode.
(Code 91: Engine speed sensor input signal)
Method of reproducing service code: Start engine.
Cause

ness
Wiring harness between NGICN2 (female) ^
Resistance Max. 1
Possible causes
defective contact in connecand standard valWiring harness between NGICN2 (female) ]
tor)
Resistance Max. 1
ue in normal state
troubleshooting.
NGICN2
Voltage
Between ^ ]
Approx 3.3 V

Cause

ness
Wiring harness between ECMB (female) O
Resistance Max. 1
Possible causes
defective contact in connecand standard valWiring harness between EG2 (male) T cirtor)
Resistance Max. 1
ue in normal state
cuit branching point
2 Defective engine controller
troubleshooting.
ECMB
Voltage
D375A-5
20-531
1
TROUBLESHOOTING
Circuit diagram related to engine speed sensor signal
20-532
1
D375A-5
TROUBLESHOOTING

User code
Service code
E01
E0931
Trouble

Contents of trouble Engine speed signal is not input from engine controller.
Action of controller Cannot recognize engine speed.

Problem that
Since engine speed signal is input to both steering controller and transmission controller, related
Related information
Inputting from engine speed sensor (Voltage) can be checked in monitoring mode.
(Code 92: Engine speed sensor input signal)
Cause

ness
Wiring harness between TMCN2 (female) ^
Resistance Max. 1
Possible causes
defective contact in connecand standard valWiring harness between TMCN2 (female) ]
tor)
Resistance Max. 1
ue in normal state
troller
troubleshooting.
TMCN2
Voltage
Between ^ ]
Approx 3.3 V

Cause

ness
Wiring harness between ECMB (female) O
Resistance Max. 1
Possible causes
defective contact in connecand standard valWiring harness between EG2 (male) T cirtor)
Resistance Max. 1
ue in normal state
ECMB
Voltage
D375A-5
20-533
1
TROUBLESHOOTING
Circuit diagram related to engine speed sensor signal
20-534
1
D375A-5
SERVICE CODE E0932 (DISCONNECTION IN TRANSMISSION SPEED SENSOR

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0932 (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)

User code
Service code
E01
E0932
Trouble

Contents of trouble Signal is not input from transmission speed sensor
Action of controller Cannot recognize transmission output speed.

Problem that
Since transmission speed signal is input to both steering controller and transmission controller, related codes may be displayed simultaneously, depending on troubled part.
Inputting from transmission speed sensor (Voltage) can be checked in monitoring mode.
Related information
(Code 94: Transmission speed sensor input signal)
When troubleshooting by operating transmission, set system in adjustment mode (Code: Co) so that
machine will not start.
Cause
Possible causes

ness
Wiring harness between TMCN2 (female) T
Resistance Max. 1
defective contact in connecWiring harness between TMCN2 (female) S
tor)
Resistance Max. 1

TMCN2 (female)
Resistance
Between T S
500 1,000
Between T chassis ground
Min. 1 M

Cause
Defective transmission
speed sensor
1
short circuit)

TM1 (male)
Resistance
Between 1 2
500 1,000
Min. 1 M

Disconnection in wiring harPossible causes
ness
and standard valWiring harness between TM1 (female) 1
Resistance Max. 1
ue in normal state 2 (Disconnection in wiring or
defective contact in connecWiring harness between TM1 (male) 2 cirtor)
Resistance Max. 1
Short circuit of wiring harness between TM1
(Contact with ground circuit) (female) 1 TMCN2 (female) T NGICN2 Resistance Min. 1 M
(female) T with chassis ground
D375A-5
20-535
1
TROUBLESHOOTING

SYSTEM)
Circuit diagram related to transmission speed sensor
20-536
1
D375A-5

SYSTEM)
TROUBLESHOOTING
SERVICE CODE E0933 (DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)

User code
Service code
E01
E0933
Trouble

Contents of trouble Signal is not input from transmission speed sensor
Action of controller Cannot recognize transmission output speed.

Problem that
Steering performance may lower.
appears on machine
Since transmission speed signal is input to both steering controller and transmission controller, related codes may be displayed simultaneously, depending on troubled part.
Inputting from transmission speed sensor (Voltage) can be checked in monitoring mode.
Related information
(Code 93: Transmission speed sensor input signal)
When troubleshooting by operating transmission, set system in adjustment mode (Code: Co) so that
machine will not start.
Cause
Possible causes

ness
Wiring harness between NGICN2 (female) T
Resistance Max. 1
defective contact in connecWiring harness between NGICN2 (female) S
tor)
Resistance Max. 1
NGICN2 (female)
Resistance
Between T S
500 1,000
Min. 1 M

Cause
Defective transmission
speed sensor
1
short circuit)

TM1 (male)
Resistance
Between 1 2
500 1,000
Min. 1 M

Disconnection in wiring harPossible causes
ness
and standard valWiring harness between TM1 (female) 1
Resistance Max. 1
ue in normal state 2 (Disconnection in wiring or
defective contact in connecWiring harness between TM1 (male) 2 cirtor)
Resistance Max. 1
Short circuit of wiring harness between TM1
(Contact with ground circuit) (female) 1 NGICN2 (female) T TMCN2 Resistance Min. 1 M
(female) T with chassis ground
D375A-5
20-537
1
TROUBLESHOOTING

SYSTEM)
Circuit diagram related to transmission speed sensor
20-538
1
D375A-5
TROUBLESHOOTING
SERVICE CODE E1939 (ABNORMALITY IN J1939 COMMUNICATION SYSTEM)
SERVICE CODE E1939 (ABNORMALITY IN J1939 COMMUNICATION SYSTEM)

User code
Service code
CALL
E1939
Trouble
Abnormality in J1939 communication system

Contents of trouble Steering controller cannot receive communication signal of J1939 communication.
Action of controller Cannot receive communication information from engine controller.

Monitoring mode of engine controller system cannot be used.
Problem that
Service codes of engine controller system cannot be recorded.
appears on machine
Engine information cannot be displayed on monitor panel normally.
Related information
J1939 communication is communication circuit between engine controller and steering controller. Although transmission controller is connected to this circuit, it does not communicate.
Cause


1
(Disconnection in wiring or de- Wiring harness between NGICN2 (female) L
Resistance Max. 1
fective contact in connector) ECMB (female) L
Possible causes
Reset according to following procedure, then check displayed service

code to see which controller is defective.
When P (reset) is displayed: Steering controller is defective.
When E (detection) is displayed: Engine controller is defective.
1)With starting switch turned OFF, exchange steering controller and
transmission controller.
Defective steering controller
2
2)Turn starting switch ON.
or engine controller
3)Set monitor panel in adjustment mode (service mode) and execute
adjustment codes [5A] and [7A].
4)Turn starting switch OFF and ON.
5)Set monitor panel in service code display mode and check displayed code.
After checking, return controllers to original states.
Circuit diagram related to J1939 communication
D375A-5
20-539
1
SERVICE CODE EC111 (ABNORMALITY IN ENGINE CONTROLLER MEMORY)

SERVICE
CODE (ABNORMALITY
EC112 (ABNORMALITY
IN TIMING
RAIL ACTUATOR)
SERVICE
CODE EC111
IN ENGINE
CONTROLLER
MEMORY)
TROUBLESHOOTING
SERVICE CODE -+ (ABNORMALITY IN ENGINE CONTROLLER MEMORY)

User code
Service code
CALL
EC111
Trouble
Abnormality in engine controller memory

(Engine controller system)
Contents of trouble Memory in controller has trouble or processor in controller has communication trouble.

Problem that
appears on machine
Cause
Possible causes
and standard value in normal state 1 Defective engine controller
Reset according to following procedure. If service code E is displayed

at this time, engine controller is defective.
1)Keep starting switch at OFF position for 5 seconds.
2)Run engine at low idling.
3)Check service code.
SERVICE CODE -+ (ABNORMALITY IN TIMING RAIL ACTUATOR)

User code
Service code
CALL
EC112
Trouble
Abnormality in timing rail actuator

Displayed fuel value of timing rail is excessively different from actual timing fuel.
Contents of trouble Judgment value (for reference):
Error is above 400 mm3/st or below 750 mm3/st (When water temperature is below 0C).

Limits engine speed to 1,500 rpm.
Problem that
Engine speed lowers.
appears on machine
Related information Method of reproducing service code: Start engine.
Cause
1 Defective related systems

Check displayed service codes. If code related to engine controller is
displayed, carry out troubleshooting for it first.
Clogging, looseness, breakCheck fuel filter/piping directly for clogging, looseness, breakage, and
2 age, or leakage of fuel filter/
leakage.
piping
Possible causes
and standard val3 Defective timing rail actuator Check timing rail actuator directly for defective operation.
ue in normal state
Clogging of timing rail actua4
Check timing rail actuator screen directly for clogging.
tor screen
20-540
1
5 Breakage of injector O-ring
Check injector O-ring directly for breakage.
If causes 1 5 are not detected, engine controller may be defective.

(Since trouble is in system, troubleshooting cannot be carried out.)
D375A-5
SERVICE CODE EC113 (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR

SYSTEM)
TROUBLESHOOTING
SERVICE CODE EC113 (ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM)

User code
Service code
CALL03
EC113
Contents of trouble
Trouble
Abnormal current in timing rail actuator system

Current in timing rail actuator is out of normal range.

Normal range (for reference): 0.40 0.35 A (When engine is stopped)

Engine output lowers.
Problem that
appears on machine Exhaust gas becomes white.
Related information
Special cable (795-799-5460) is necessary for troubleshooting for timing rail actuator.
Method of reproducing service code: Turn starting switch ON (or start engine).
Cause

Possible causes
Defective timing rail actuator

(Internal trouble)
TIMG (male)
Resistance
Between A, C chassis ground
Min. 100 k
Between A C
79

ness
Wiring harness between ECMA (female) 1
Resistance Max. 10
TIMG (female) A
defective contact in connecWiring harness between ECMA (female) J
tor)
Resistance Max. 10
TIMG (female) C
3
Short circuit of wiring harness between ECMA

(female) 1 TIMG (female) A with wiring
Resistance Min. 1 M
harness around it
(female) J TIMG (female) C with wiring
Resistance Min. 1 M
harness around it
ECMA (female)
Resistance
Between 1 J
79
Wiring harness between 1, J

wiring harness around it
Min. 1 M
Circuit diagram related to timing rail actuator
D375A-5
20-541
(7)
1
TROUBLESHOOTING
SERVICE CODE EC115 (ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)

User code
Service code
CALL
EC115
Trouble
Abnormality in engine speed sensor 2 systems

Contents of trouble Signal is not input to either of engine speed sensor circuit 2 systems.

Outputs speed signal of 0 rpm.
Problem that
Engine stops.
appears on machine
Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
(Code 62: Engine speed)
Related information
Special cable (795-799-5520) is necessary for troubleshooting for engine speed sensor.
Cause

Defective engine speed sen1 sor

(Internal trouble)
SP1 (male), SP2 (male)
Resistance
Between A A
Max. 10
Between A B
Between B B
Between A chassis ground

Damage of engine speed
2
sensor
1 k 2 k
Max. 10
Min. 10 M
Check engine speed sensor directly.


Wiring harness between ECMA (female) Q

Resistance Max. 10
SP1 (female) A
Wiring harness between ECMA (female) R
Resistance Max. 10
SP1 (female) B
Wiring harness between ECMA (female) [
Resistance Max. 10
SP2 (female) A
Wiring harness between ECMA (female) \
Resistance Max. 10
SP2 (female) B
Possible causes

(female) Q SP1 (female) A with wiring har- Resistance Min. 1 M
ness around it
4

(female) R SP1 (female) B with wiring har- Resistance Min. 1 M
ness around it
(female) [ SP2 (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) \ SP2 (female) B with wiring har- Resistance Min. 1 M
ness around it
troubleshooting.
ECMA (female)
20-542
1
Resistance
Between Q R
1 k 2 k
Between Q, R chassis ground
Min. 1 M
Between [ \
1 k 2 k
Between [, \ chassis ground
Min. 1 M
D375A-5
TROUBLESHOOTING
Circuit diagram related to engine speed sensor
D375A-5
20-543
1
TROUBLESHOOTING
SERVICE CODE EC116 (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE

SENSOR SYSTEM)
SERVICE CODE EC116 (ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL
EC116
Trouble
Abnormally high level in timing rail pressure sensor system

Contents of trouble Signal voltage of timing rail pressure sensor circuit is above 4.78 V.

Action of controller Opens and controls timing rail.
Problem that
Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
1,500 rpm.
appears on machine
Related information
Special cable (795-799-5480) is necessary for troubleshooting for timing rail pressure sensor.
Cause
Defective timing rail pres1 sure sensor
(Internal trouble)

Possible causes

TPR
Between A B
Between C B
Voltage
4.75 5.25 V
0.42 0.58 V

Resistance Max. 10
TPR (female) A
Wiring harness between ECMA (female) H
Resistance Max. 10
TPR (female) B
Wiring harness between ECMA (female) W
Resistance Max. 10
TPR (female) C

3

(female) 5 TPR (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) H TPR (female) B with wiring har- Resistance Min. 1 M
ness around it
(female) W TPR (female) C with wiring har- Resistance Min. 1 M
ness around it
ECMA
Voltage
Between 5 H
4.75 5.25 V
Between W H
0.42 0.58 V
Circuit diagram related to engine speed sensor
20-544
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE EC117 (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE

SENSOR SYSTEM)
SERVICE CODE EC117 (ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL
EC117
Trouble
Abnormally low level in timing rail pressure sensor system

Contents of trouble Signal voltage of timing rail pressure sensor circuit is below 0.30 V.

Action of controller Opens and controls timing rail.
Engine makes abnormal combustion sound or discharges white smoke, then its speed is set to
Problem that
appears on machine
1,500 rpm.
Possible causes
D375A-5
Cause

Carry out troubleshooting for service code [EC116].
20-545
1
TROUBLESHOOTING
SERVICE CODE EC118 (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE

SENSOR SYSTEM)
SERVICE CODE EC118 (ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL03
EC118
Trouble
Abnormally high level in fuel pump pressure sensor system

Contents of trouble Signal voltage of fuel pump pressure sensor circuit is above 4.78 V.

Opens and controls fuel pump.
Problem that
appears on machine
Related information
Special cable (795-799-5480) is necessary for troubleshooting for fuel pump pressure sensor.
Cause
Defective fuel pump pres1 sure sensor
(Internal trouble)

Possible causes

PMPR (male)
Between A B
Between C B
Voltage
4.75 5.25 V
0.42 0.58 V

Resistance Max. 10
PMPR (female) A
Resistance Max. 10
PMPR (female) B
Wiring harness between ECMA (female) V
Resistance Max. 10
PMPR (female) C

3

(female) 5 PMPR (female) A with wiring Resistance Min. 1 M
harness around it
(female) H PMPR (female) B with wiring Resistance Min. 1 M
harness around it
(female) V PMPR (female) C with wiring Resistance Min. 1 M
harness around it
ECMA (female)
Resistance
Between 5 H
4.75 5.25 V
Between V H
0.42 0.58 V
Circuit diagram related to fuel pump pressure sensor
20-546
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE

SYSTEM)
SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUELSENSOR
PUMP PRESSURE
SERVICE CODE EC121 (ABNORMALITY IN ENGINE SPEED SENSOR
1 SYSTEMS)
SENSOR
SYSTEM)
SERVICE CODE EC119 (ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL03
EC119
Trouble
Abnormally low level in fuel pump pressure sensor system

Contents of trouble Signal voltage of fuel pump pressure sensor circuit is below 0.30 V.

Opens and controls fuel pump.
Problem that
appears on machine
Possible causes
Cause


User code
Service code
CALL03
EC121
Trouble
Abnormality in engine speed sensor 1 systems

Contents of trouble Signal is not input to both of engine speed sensor circuit 2 systems.

Problem that
appears on machine
Related information
Possible causes
D375A-5
Inputting from engine speed sensor (rpm) can be checked in monitoring mode.
(Code 62: Engine speed)
Cause

20-547
1
SERVICE CODE EC122 (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE

SENSOR SYSTEM)
TROUBLESHOOTING
SERVICE CODE EC122 (ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR

SYSTEM)
User code
Service code
E01
EC122
Trouble
Abnormally high level in boost pressure sensor system

Contents of trouble Signal voltage of boost pressure sensor circuit is above 4.72 V.
When machine is accelerated sharply, exhaust gas color is bad.
Problem that
appears on machine Engine output rises.
Related information
Special cable (795-799-5480) is necessary for troubleshooting for boost pressure sensor.
Cause
Defective boost pressure
1 sensor
(Internal trouble)

Possible causes

IMPR (male)
Between A B
Between C B
Voltage
4.72 5.25 V
0.42 0.58 V

Resistance Max. 10
IMPR (female) A
Wiring harness between ECMA (female) G
Resistance Max. 10
IMPR (female) B
Wiring harness between ECMA (female) Y
Resistance Max. 10
IMPR (female) C

3

Resistance Min. 1 M
(female) 6 IMPR (female) A with wiring
harness around it
Resistance Min. 1 M
(female) G IMPR (female) B with wiring
harness around it
Resistance Min. 1 M
(female) Y IMPR (female) C with wiring
harness around it
ECMA
Voltage
Between 6 G
4.75 5.25 V
Between Y G
0.42 0.58 V
Circuit diagram related to boost pressure sensor
20-548
(7)
1
D375A-5
TROUBLESHOOTING
SERVICE CODE EC123 (ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR

SYSTEM)
SERVICE CODE -+ ! (ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR

SYSTEM)
User code
Service code
E01
EC123
Trouble
Abnormally low level in boost pressure sensor system

Contents of trouble Signal voltage of boost pressure sensor circuit is below 0.30 V.
Problem that
Engine output lowers.
appears on machine
Possible causes
D375A-5
Cause

20-549
1
SERVICE CODE EC131 (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR

SYSTEM)
TROUBLESHOOTING
SERVICE CODE -+! (ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM)

User code
Service code
CALL
EC131
Trouble
Abnormally high level in throttle sensor system

Contents of trouble Signal voltage of throttle sensor (deceleration potentiometer) circuit is above 4.80 V.

Keeps engine speed at constant level.
Problem that
Engine output and speed rise suddenly.
appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode.
Related information
(Code d6: Deceleration potentiometer voltage)
Cause

Defective deceleration po1 tentiometer

(Internal trouble)
DCL (male)
Resistance
Between A B
0.25 7.0 k
Between A C
Between B C
Possible causes

4.0 6.0 k
0.25 7.0 k

Wiring harness between ECMB (female) P
Resistance Max. 10
DCL (female) A
Wiring harness between ECMB (female) A
Resistance Max. 10
DCL (female) C
Wiring harness between ECMB (female) S
Resistance Max. 10
DCL (female) B

3
Short circuit of wiring harness between ECMB

(female) P DCL (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) A DCL (female) C with wiring har- Resistance Min. 1 M
ness around it
(female) S DCL (female) B with wiring har- Resistance Min. 1 M
ness around it
ECMB
Voltage
Between S A
0.30 4.80 V
Circuit diagram related to deceleration potentiometer
20-550
1
D375A-5
SERVICE CODE EC132 (ABNORMALLY LOW LEVEL IN THROTTLE SENSOR

SYSTEM)
TROUBLESHOOTING
SERVICE CODE -+!
(ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM)
User code
Service code
CALL
EC132
Trouble
Abnormally low level in throttle sensor system

Contents of trouble Signal voltage of throttle sensor (deceleration potentiometer) circuit is below 0.30 V.

Problem that
Engine speed and output lower suddenly.
appears on machine
Inputting from deceleration potentiometer to steering controller (Voltage) can be checked in monitoring mode.
Related information
(Code d6: Deceleration potentiometer voltage)
Possible causes
D375A-5
Cause

20-551
1
SERVICE CODE EC133 (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE

SENSOR SYSTEM)
TROUBLESHOOTING
SERVICE CODE -+!! (ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE SENSOR

SYSTEM)
User code
Service code
CALL
EC133
Trouble
Abnormally high level in remote throttle sensor system

Contents of trouble Signal voltage of remote throttle sensor (SSC command) circuit is above 4.80 V.

Problem that
Engine speed rises suddenly.
appears on machine
Related information
Outputting of SSC command to steering controller (Voltage) can be checked in monitoring mode.
(Code 5U: Engine command voltage)
Cause


1
(Disconnection in wiring or de- Wiring harness between ECMB (female) T
Resistance Max. 10
fective contact in connector) NGICN2 (female) A
2
Possible causes

(female) T NGICN2 (female) A with wiring Resistance Min. 1 M
harness around it
Reset according to following procedure, then check displayed service
code to see which controller is defective.
When P (reset) is displayed: Steering controller is defective.
When E (detection) is displayed: Engine controller is defective.
Defective engine controller

or steering controller
1)With starting switch turned OFF, exchange steering controller and

transmission controller.
2)Turn starting switch ON.
3)Set monitor panel in adjustment mode (service mode) and execute
adjustment codes [5A] and [7A].
4)Turn starting switch OFF and ON.
5)Set monitor panel in service code display mode and check displayed code.
After checking, return controllers to original states.
Circuit diagram related to SSC command
20-552
1
D375A-5
SERVICE CODE EC134 (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE

SENSOR SYSTEM)
TROUBLESHOOTING
SERVICE CODE -+!" (ABNORMALLY LOW LEVEL IN REMOTE THROTTLE SENSOR

SYSTEM)
User code
Service code
CALL
EC134
Trouble
Abnormally low level in remote throttle sensor system

Contents of trouble Signal voltage of remote throttle sensor (SSC command) circuit is below 0.30 V.

Problem that
Engine speed lowers suddenly.
appears on machine
Related information
Possible causes
D375A-5
Outputting of SSC command to steering controller (Voltage) can be checked in monitoring mode.
(Code 5U: Engine command voltage)
Cause

20-553
1
TROUBLESHOOTING
SERVICE CODE EC135 (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE

SENSOR SYSTEM)
SERVICE CODE -+!# (ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL03
EC135
Trouble
Abnormally high level in engine oil pressure sensor system

Contents of trouble Signal voltage of engine oil pressure sensor circuit is above 4.88 V.

Problem that
appears on machine
Related information
Special cable (795-799-5470) is necessary for troubleshooting for engine oil pressure sensor.
Cause
Defective engine oil pres1 sure sensor
(Internal trouble)

Possible causes

OLPR
Between A B
Between C B
Voltage
4.75 5.25 V
0.42 0.58 V

Resistance Max. 10
OLPR (female) A
Resistance Max. 10
OLPR (female) B
Wiring harness between ECMA (female) N
Resistance Max. 10
OLPR (female) C

3

Resistance Min. 1 M
(female) 6 OLPR (female) A with wiring
harness around it
Resistance Min. 1 M
(female) G OLPR (female) B with wiring
harness around it
Resistance Min. 1 M
(female) N OLPR (female) C with wiring
harness around it
ECMA
Voltage
Between 6 G
4.75 5.25 V
Between N G
0.42 0.58 V
Circuit diagram related to engine oil pressure sensor
20-554
1
D375A-5
TROUBLESHOOTING
SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE

SENSOR
SYSTEM)
SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE
OIL PRESSURE
SERVICE CODE EC143 (LOWERING OF ENGINE
OIL PRESSURE)
SENSOR
SYSTEM)
SERVICE CODE EC141 (ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL03
EC141
Trouble
Abnormally low level in engine oil pressure sensor system

Contents of trouble Signal voltage of engine oil pressure sensor circuit is below 0.31 V.

Problem that
appears on machine
Possible causes
Cause

SERVICE CODE EC143 (LOWERING OF ENGINE OIL PRESSURE)

User code
Service code
EC143
Trouble
Lowering of engine oil pressure

Engine oil pressure sensor detected pressure lower than pressure set in controller.
Criterion (for reference): Max. 0.05 MPa {0.5 kg/cm2} at 600 rpm
Max. 0.09 MPa {0.9 kg/cm2} at 1,000 rpm
Contents of trouble
Action of controller Limits fuel injection rate to 50% after 10 seconds.
Problem that
appears on machine
Cause
Possible causes
and standard value in normal state 2 Defective engine oil pressure sensor system
3 Defective engine
D375A-5

Carry out troubleshooting for service codes [EC135] and [EC141].
See S mode.
20-555
(5)
1
SERVICE CODE EC144 (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT

TEMPERATURE SENSOR SYSTEM)
TROUBLESHOOTING
SERVICE CODE EC144 (ABNORMALLY HIGH LEVEL IN ENGINE COOLANT

User code
Service code
CALL03
EC144
Trouble
Abnormally high level in engine coolant temperature sensor system

Contents of trouble Signal voltage of engine coolant temperature sensor circuit is above 4.95 V.

Problem that
appears on machine
Related information
Special cable (795-799-5530) is necessary for troubleshooting for engine coolant temperature sensor.
Cause
Defective engine coolant
1 temperature sensor
(Internal trouble)
Possible causes

CLTP
Between A B
Resistance
600 36 k

ness
Wiring harness between ECMA (female) L
Resistance Max. 10
CLTP (female) A
defective contact in connecWiring harness between ECMA (female) G
tor)
Resistance Max. 10
CLTP (female) B
3

(female) L CLTP (female) A with wiring
Resistance Min. 1 M
harness around it
Resistance Min. 1 M
(female) G CLTP (female) B with wiring
harness around it
ECMA (female)
Resistance
Between N G
600 36 k
Circuit diagram related to engine coolant temperature sensor
20-556
1
D375A-5
SERVICE CODE EC145 (ABNORMALLY LOW LEVEL IN ENGINE COOLANT

SENSORCOOLANT
SYSTEM)
SERVICE CODE EC145 (ABNORMALLYTEMPERATURE
LOW LEVEL IN ENGINE
SERVICE CODE EC151 (RISE OF ENGINE
COOLANT
TEMPERATURE)
TEMPERATURE
SENSOR
SYSTEM)
TROUBLESHOOTING
SERVICE CODE EC145 (ABNORMALLY LOW LEVEL IN ENGINE COOLANT

User code
Service code
CALL03
EC145
Trouble
Abnormally low level in engine coolant temperature sensor system

Contents of trouble Signal voltage of engine coolant temperature sensor circuit is below 0.21 V.

Problem that
appears on machine
Possible causes
Cause

SERVICE CODE EC151 (RISE OF ENGINE COOLANT TEMPERATURE)

User code
Service code
EC151
Contents of trouble
Trouble
Rise of engine coolant temperature

Engine coolant temperature sensor detected temperature higher than temperature set in controller.
Criterion (for reference): Min. 105C
Action of controller Limits fuel injection rate to 50% after 10 seconds.

Problem that
appears on machine
Cause


Possible causes
and standard value in normal state 2 Defective engine coolant
temperature sensor system
3 Defective engine
D375A-5
See S mode.
20-557
(5)
1
TROUBLESHOOTING
SERVICE CODE EC153 (ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE

SENSOR SYSTEM)
SERVICE CODE EC153 (ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE

SENSOR SYSTEM)
User code
Service code
CALL03
EC153
Trouble
Abnormally high level in air intake temperature sensor system

Contents of trouble Signal voltage of air intake temperature sensor circuit is above 4.88 V.

Problem that
appears on machine
Related information
Special cable (795-799-5540) is necessary for troubleshooting for air intake temperature sensor.
Cause
Defective air intake tempera1 ture sensor
(Internal trouble)
Possible causes

IMTP (female)
Between A B
Resistance
36 600

ness
Wiring harness between ECMA (female) M
Resistance Max. 10
IMTP (female) A
tor)
Resistance Max. 10
IMTP (female) B
3

(female) M IMTP (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) G IMTP (female) B with wiring har- Resistance Min. 1 M
ness around it
ECMA (female)
Resistance
Between M G
36 600
Circuit diagram related to air intake temperature sensor
20-558
1
D375A-5
TROUBLESHOOTING
SERVICE CODE EC154 (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE

SENSOR SYSTEM)
SERVICE CODE -+#" (ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE

SENSOR SYSTEM)
User code
Service code
CALL03
EC154
Trouble
Abnormally low level in air intake temperature sensor system

Contents of trouble Signal voltage of air intake temperature sensor circuit is below 0.08 V.

Problem that
appears on machine
Possible causes
D375A-5
Cause

20-559
1
TROUBLESHOOTING
SERVICE CODE EC221 (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE

SENSOR SYSTEM)
SERVICE CODE -+ (ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL03
EC221
Trouble
Abnormally high level in atmospheric pressure sensor system

Contents of trouble Signal voltage of atmospheric pressure sensor circuit is above 4.78 V.

Problem that
appears on machine
Related information
Special cable (795-799-5460) is necessary for troubleshooting for atmospheric pressure sensor.
Cause
Defective atmospheric pres1 sure sensor
(Internal trouble)

Possible causes

AAPR
Between A B
Between C B
Voltage
4.75 5.25 V
0.42 0.58 V

Resistance Max. 10
AAPR (female) A
Resistance Max. 10
AAPR (female) B
Wiring harness between ECMA (female) X
Resistance Max. 10
AAPR (female) C

3

Resistance Min. 1 M
(female) 6 AAPR (female) A with wiring
harness around it
Resistance Min. 1 M
(female) G AAPR (female) B with wiring
harness around it
Resistance Min. 1 M
(female) X AAPR (female) C with wiring
harness around it
ECMA
Voltage
Between 6 G
4.75 5.25 V
Between X G
0.42 0.58 V
Circuit diagram related to atmospheric pressure sensor
20-560
1
D375A-5
TROUBLESHOOTING
SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE

SENSOR
SYSTEM)
SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC
PRESSURE
SERVICE CODE EC234
(OVER-SPEED)
SENSOR
SYSTEM)
SERVICE CODE EC222 (ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL03
EC222
Trouble
Abnormally low level in atmospheric pressure sensor system

Contents of trouble Signal voltage of atmospheric pressure sensor circuit is below 0.20 V.

Problem that
appears on machine
Possible causes
Cause

SERVICE CODE EC234 (OVER-SPEED)

User code
Service code
EC234
Contents of trouble
Trouble
Over-speed
Engine speed sensor detected speed higher than speed set in controller.
Criterion (for reference): Min. 2,400 rpm
Action of controller Closes fuel rail actuator fully (Cuts out fuel).
Problem that
appears on machine
Cause
Possible causes
and standard val- 1 Defective related systems
ue in normal state
2 Defective engine
D375A-5

See S mode.
20-561
(5)
1
TROUBLESHOOTING
SERVICE CODE EC254 (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)
SERVICE CODE EC254 (ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)

User code
Service code
E01
EC254
Trouble
Abnormal voltage of fuel shut-off valve

Contents of trouble Voltage (Resistance) of fuel shut-off valve circuit is above 6.0 V (below 20 ).
Action of controller Turns off power for fuel shut-off valve.

Problem that
Engine stops.
appears on machine
Cause

Possible causes
Defective fuel shut-off valve

(Internal trouble)
FSO (Valve side)
Resistance
Between (+) ()
23 40
Between (+) chassis ground
100 k

ness
Wiring harness between ECMA (female) T
Resistance Max. 10
FSO (wiring harness side) (+)
defective contact in connecWiring harness between FSO (wiring harness
tor)
Resistance Max. 10
side) () chassis ground
3

(female) T FSO (wiring harness side) (+) Resistance Min. 1 M
with wiring harness around it
Short circuit of wiring harness between FSO
Resistance Min. 1 M
(wiring harness side) () chassis ground
with wiring harness around it
ECMA
Resistance
23 40
Circuit diagram related to fuel shut-off valve
20-562
1
D375A-5
SERVICE CODE EC259 (ABNORMALITY IN FUEL SHUT-OFF VALVE)

SERVICE
RISEINOF
FUEL
TEMPERATURE)
SERVICECODE
CODE EC261
EC259 (ABNORMAL
(ABNORMALITY
FUEL
SHUT-OFF
VALVE)
TROUBLESHOOTING
SERVICE CODE EC259 (ABNORMALITY IN FUEL SHUT-OFF VALVE)

User code
Service code
CALL
EC259
Trouble
Abnormality in fuel shut-off valve

Contents of trouble Fuel shut-off valve cannot be closed (Engine does not stop when electric power is turned off).

Turns off power for fuel shut-off valve.
Problem that
Engine cannot be stopped.
appears on machine
Cause

2 Trouble in fuel shut-off valve Check inside of fuel shut-off valve directly.
Possible causes
Clogging, looseness, breakand standard valCheck fuel filter/piping directly for clogging, looseness, breakage, and
3
age, or leakage of fuel filter/
ue in normal state
leakage.
piping
4 Trouble in injector
Check inside of injector directly.

SERVICE CODE EC261 (ABNORMAL RISE OF FUEL TEMPERATURE)

User code
Service code
EC261
Contents of trouble
Trouble
Abnormal rise of fuel temperature

Fuel temperature sensor detected temperature lower than temperature set in controller.
Criterion (for reference): Min. 76C
Action of controller Limits engine speed to 800 rpm after 30 seconds.

Problem that
appears on machine
Cause
Possible causes
and standard value in normal state 2 Defective fuel temperature
sensor system
3 Defective engine
D375A-5

See S mode.
20-563
(5)
1
SERVICE CODE EC263 (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE

SENSOR SYSTEM)
TROUBLESHOOTING
SERVICE CODE EC263 (ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR

SYSTEM)
User code
Service code
CALL03
EC263
Trouble
Abnormally high level in fuel temperature sensor system

Contents of trouble Signal voltage of fuel temperature sensor circuit is above 4.95 V.

Problem that
appears on machine
Related information
Special cable (795-799-5530) is necessary for troubleshooting for fuel temperature sensor.
Cause
Defective fuel temperature
1 sensor
(Internal trouble)
Possible causes

FLTP (female)
Between A B
Resistance
600 36 k

ness
Wiring harness between ECMA (female) P
Resistance Max. 10
FLTP (female) A
tor)
Resistance Max. 10
FLTP (female) B
3

(female) P FLTP (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) G FLTP (female) B with wiring har- Resistance Min. 1 M
ness around it
ECMA (female)
Resistance
Between P G
600 36 k
Circuit diagram related to fuel temperature sensor
20-564
1
D375A-5
SERVICE CODE EC265 (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE

SENSOR SYSTEM)
TROUBLESHOOTING
SERVICE CODE -+ $# (ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR

SYSTEM)
User code
Service code
CALL03
EC265
Trouble
Abnormally low level in fuel temperature sensor system

Contents of trouble Signal voltage of fuel temperature sensor circuit is below 0.21 V.

Problem that
appears on machine
Possible causes
D375A-5
Cause

20-565
1
TROUBLESHOOTING
SERVICE CODE EC316 (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)
SERVICE CODE -+!$ (ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)

User code
Service code
CALL03
EC316
Contents of trouble
Trouble
Abnormal current of fuel pump actuator

Current of fuel pump actuator circuit is out of normal range.


Problem that
appears on machine
Related information
Special cable (795-799-5470) is necessary for troubleshooting for fuel pump actuator.
Cause
Defective fuel pump actuator

(Internal trouble)

PUMP (male)
Between A C
Possible causes
Resistance
79
Min. 100 k

ness
Wiring harness between ECMA (female) A
Resistance Max. 10
PUMP (female) A
defective contact in connecWiring harness between ECMA (female) ^
tor)
Resistance Max. 10
PUMP (female) C
3

(female) A PUMP (female) A with wiring Resistance Min. 1 M
harness around it
(female) ^ PUMP (female) C with wiring Resistance Min. 1 M
harness around it
ECMA (female)
Resistance
Between A ^
79
Between A, ^ another wiring

harness
Min. 1 M
Circuit diagram related to fuel pump actuator
20-566
1
D375A-5
TROUBLESHOOTING
SERVICE CODE EC318 (ABNORMALITY IN FUEL PUMP ACTUATOR)
SERVICE CODE EC318 (ABNORMALITY IN FUEL PUMP ACTUATOR)

User code
Service code
CALL03
EC318
Contents of trouble
Trouble
Abnormality in fuel pump actuator

Displayed pressure of fuel pump is excessively different from actual value.

Criteria for difference (for reference): 0.21 MPa {2.1 kg/cm2} (when water temperature is 38C)

Problem that
Engine speed is unstable.
appears on machine
Cause

leakage.
piping
3
Suction of air caused by low Air may be sucked because of lowering of fuel level in tank. If fuel level
fuel level in tank
gauge is in red range, supply fuel.
Suction resistance of fuel filter may be large. Check fuel filter directly.
Possible causes
and standard valLarge suction resistance of
4
ue in normal state
fuel filter
D375A-5
Fuel pump
inlet pressure
Engine high
idling
When new
filter is used
Max. 13.6 kPa

{Max. 102 mmHg}
Normal
condition
Max. 27.1 kPa

{Max. 203 mmHg}
Trouble in fuel pump actuaFuel pump actuator may malfunction. Check it directly.
tor
Defective electric system of

fuel pump pressure sensor
7 Trouble in injector
Inside of injector may be defective. Check it directly.

20-567
(5)
1
SERVICE CODE EC346 (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE

CONTROLLER)
TROUBLESHOOTING

CONTROLLER)
User code
Service code
CALL03
EC346
Trouble
Abnormality in power-down unit of engine controller

Contents of trouble Data recorded in power-down unit of engine controller has error.

Power-down data (maintenance information, current controller information, engine operating hours,
Problem that
appears on machine
etc.) are lost.
Related information
Charge level of battery (Voltage) can be checked in monitoring mode.

Cause
1 Defective fusible link (34 A)
ground.
Defective fuse
(FS1-1, FS1-4)
If fuse is broken, circuit probably has short circuit with chassis ground.

Possible causes
Wiring harness between ECMB (female) 3

Resistance Max. 10
FS1-3 outlet
Wiring harness between ECMA (female) 4,
5 FS1-4 outlet
Resistance Max. 10
Wiring harness between FS1 inlet fusible

link battery relay terminal B
Resistance Max. 10


4

(female) 3 FS1-3 outlet with wiring harness Resistance Min. 1 M
around it
(female) 4, 5 FS1-4 outlet with wiring har- Resistance Min. 1 M
ness around it
Wiring harness between FS1 inlet fusible
link battery relay terminal B with wiring har- Resistance Min. 1 M
ness around it
20-568
1
ECMA, ECMB
Voltage
Between ECMB 3, 4, 5
ECMA 7, 8
17.3 34.7 V
D375A-5
TROUBLESHOOTING

CONTROLLER)
Circuit diagram related to engine controller power supply
D375A-5
20-569
1
TROUBLESHOOTING
SERVICE CODE EC384 (ABNORMALITY IN PREHEATER CONTROL SYSTEM)
SERVICE CODE -+!&" (ABNORMALITY IN PREHEATER CONTROL SYSTEM)

User code
Service code
CALL03
EC384
Trouble
Abnormality in preheater control system

Contents of trouble Disconnection or short circuit was detected in preheater control circuit.

Problem that
appears on machine
Cause
Defective preheater relay
1
(Internal trouble)

RHR (male)
Resistance
Between 1 2
200 400

ness
Resistance Max. 10
RHR (female) 1
defective contact in connecWiring harness between RHR (female) 2
tor)
Resistance Max. 10
chassis ground
Possible causes

3

(female) 2 RHR (female) 1 with wiring har- Resistance Min. 1 M
ness around it
Short circuit of wiring harness between RHR
(female) 2 chassis ground with wiring har- Resistance Min. 1 M
ness around it
20-570
1
ECMA (female)
Resistance
200 400
Between 2 another wiring

harness
Min. 1 M
D375A-5
TROUBLESHOOTING
SERVICE CODE EC384 (ABNORMALITY IN PREHEATER CONTROL SYSTEM)
Circuit diagram related to preheater control
D375A-5
20-571
1
TROUBLESHOOTING
SERVICE CODE EC423 (ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE

SENSOR SYSTEM)

SENSOR SYSTEM)
User code
Service code
CALL03
EC423
Contents of trouble
Trouble
Abnormality in in-range of timing rail pressure sensor system

Timing rail pressure sensor detected abnormal pressure.

Criterion (for reference): Min. 2.42 MPa {24.65 kg/cm2} when starting switch is turned on
Limits high idling speed to 1,500 rpm.
Problem that
appears on machine
Related information
Special cable (799-795-5460) is necessary for troubleshooting for timing rail pressure sensor.
Cause
Defective timing rail pres1 sure sensor
(Internal trouble)

TIMG (male)
Voltage
Between C B
4.75 5.25 V
Between A B
0.42 0.58 V


Resistance Max. 10
TPR (female) A
Resistance Max. 10
TPR (female) B
Wiring harness between ECMA (female) W
Resistance Max. 10
TPR (female) C
Possible causes

3

(female) 5 TPR (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) H TPR (female) B with wiring har- Resistance Min. 1 M
ness around it
(female) W TPR (female) C with wiring har- Resistance Min. 1 M
ness around it
Large suction resistance of

fuel filter
Fuel pump
inlet pressure
Engine high
idling
When new
filter is used
Max. 13.6 kPa

{Max. 102 mmHg}
Normal
condition
Max. 27.1 kPa

{Max. 203 mmHg}
20-572
(5)
1
ECMA (female)
Resistance
Between 5 H
4.75 5.25 V
Between W H
0.42 0.58 V
D375A-5
TROUBLESHOOTING

SENSOR SYSTEM)
Circuit diagram related to timing rail pressure sensor
D375A-5
20-573
1
SERVICE
CODE
EC441
(ABNORMALLY
LOW LEVEL
IN BATTERY
VOLTAGE
SYSTEM)
SERVICE
CODE
EC441
(ABNORMALLY
LOW LEVEL
IN BATTERY
VOLTAGE
SERVICE CODE EC442 (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGESYSTEM)
SYSTEM)
TROUBLESHOOTING
SERVICE CODE -+"" (ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM)

User code
Service code
E01
EC441
Trouble
Abnormally low level in battery voltage system

Contents of trouble Voltage of controller power supply circuit is below 12 V.
Problem that
appears on machine
Possible causes
Cause

SERVICE CODE -+"" (ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM)

User code
Service code
E01
EC442
Trouble
Abnormally high level in battery voltage system

Contents of trouble Voltage of controller power supply circuit is below 38 V.
Problem that
appears on machine
Possible causes
20-574
1
Cause

D375A-5
TROUBLESHOOTING
SERVICE CODE EC451 (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE

SENSOR SYSTEM)
SERVICE CODE -+"# (ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR
SYSTEM)
User code
Service code
CALL
EC451
Trouble
Abnormally high level in fuel rail pressure sensor system

Contents of trouble Signal voltage of fuel rail pressure sensor circuit is above 4.78 V.

Opens and controls fuel rail.
Problem that
appears on machine
Related information
Special cable (795-799-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Cause
Defective fuel rail pressure
1 sensor
(Internal trouble)

Possible causes

RPR
Between A B
Between C B
Voltage
4.75 5.25 V
0.42 0.58 V

Resistance Max. 10
RPR (female) A
Resistance Max. 10
RPR (female) B
Wiring harness between ECMA (female) U
Resistance Max. 10
RPR (female) C

3

(female) 5 RPR (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) H RPR (female) B with wiring har- Resistance Min. 1 M
ness around it
(female) U RPR (female) C with wiring har- Resistance Min. 1 M
ness around it
ECMA
Voltage
Between 5 H
4.75 5.25 V
Between U H
0.42 0.58 V
Circuit diagram related to fuel rail pressure sensor
D375A-5
20-575
1
TROUBLESHOOTING
SERVICE CODE EC452 (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE

SENSOR SYSTEM)
SERVICE CODE -+"# (ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR
SYSTEM)
User code
Service code
CALL
EC452
Trouble
Abnormally low level in fuel rail pressure sensor system

Contents of trouble Signal voltage of fuel rail pressure sensor circuit is below 0.15 V.

Reduces current for fuel rail actuator to 0 A.
Problem that
appears on machine
Possible causes
20-576
1
Cause

D375A-5
TROUBLESHOOTING
SERVICE CODE EC455 (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)
SERVICE CODE -+"## (ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)

User code
Service code
CALL
EC455
Contents of trouble
Trouble
Abnormal current of fuel rail actuator

Current of fuel rail actuator circuit is out of normal range.

Problem that
appears on machine
Related information
Special cable (795-799-5470) is necessary for troubleshooting for fuel rail actuator.
Method of reproducing service code: Turn starting switch ON or start engine.
Cause
Defective fuel rail actuator

(Internal trouble)

RAIL (male)
Between A C
Possible causes
Resistance
79
Min. 100 k

ness
Resistance Max. 10
RAIL (female) A
defective contact in connecWiring harness between ECMA (female) @
tor)
Resistance Max. 10
RAIL (female) C
3

(female) 3 RAIL (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) @ RAIL (female) C with wiring har- Resistance Min. 1 M
ness around it
ECMA (female)
Resistance
Between 3 @
79
Between 3, @ another wiring

harness
Min. 1 M
Circuit diagram related to fuel rail actuator
D375A-5
20-577
1
TROUBLESHOOTING
SERVICE CODE EC467 (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)

SERVICE
CODEEC467
EC468(ABNORMALITY
(ABNORMALITY
FUEL RAIL ACTUATOR CONTROL)
SERVICE
CODE
ININ
TIMING
SERVICE CODE -+"$% (ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)

User code
Service code
CALL03
EC467
Contents of trouble
Trouble
Abnormality in timing rail actuator control

Displayed timing rail fuel value is so different from quantity of actual timing fuel that target value cannot be obtained.
Problem that
appears on machine
Possible causes
Cause

SERVICE CODE -+"$& (ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)

User code
Service code
CALL03
EC468
Contents of trouble
Trouble
Abnormality in fuel rail actuator control

Displayed injection rate of fuel rail is so different from actual injection rate that target value cannot be
obtained.
Limits maximum injection rate to 217 mm3/st.
Problem that
appears on machine
Cause

leakage.
piping
Possible causes
and standard val3 Trouble in fuel rail actuator Fuel pump actuator may have trouble in it. Check it directly.
ue in normal state
Clogging of fuel rail actuator
4
Fuel rail actuator screen may be clogged. Check it directly.
screen
20-578
1
5 Breakage of injector O-ring
Injector O-ring may be broken. Check it directly.

D375A-5
TROUBLESHOOTING
SERVICE CODE EC514 (ABNORMALITY IN FUEL RAIL ACTUATOR)
SERVICE CODE -+#" (ABNORMALITY IN FUEL RAIL ACTUATOR)

User code
Service code
CALL
EC514
Contents of trouble
Trouble
Abnormality in fuel rail actuator

Displayed injection rate of fuel rail is excessively different from actual injection rate.
Criterion (for reference): Difference is 600 mm3/st for 50 msec or 250 mm3/st for 200 msec.
Problem that
appears on machine
Possible causes
D375A-5
Cause

20-579
1
TROUBLESHOOTING
SERVICE CODE EC554 (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE

SENSOR SYSTEM)
SERVICE CODE -+##" (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE

SENSOR SYSTEM)
User code
Service code
CALL05
EC554
Contents of trouble
Trouble
Abnormality in in-range of fuel rail pressure sensor system

Fuel rail pressure sensor detected abnormal pressure.

Criterion (for reference): Min. 0.17 MPa {1.76 kg/cm2} when starting switch is turned on
Problem that
appears on machine
Related information
Special cable (799-795-5460) is necessary for troubleshooting for fuel rail pressure sensor.
Cause
Defective fuel rail pressure
1 sensor
(Internal trouble)

Possible causes

RPR
Between A B
Between C B
Voltage
4.75 5.25 V
0.42 0.58 V

Resistance Max. 10
RPR (female) A
Resistance Max. 10
RPR (female) B
Wiring harness between ECMA (female) U
Resistance Max. 10
RPR (female) C

3

(female) 5 RPR (female) A with wiring har- Resistance Min. 1 M
ness around it
(female) H RPR (female) B with wiring har- Resistance Min. 1 M
ness around it
(female) U RPR (female) C with wiring har- Resistance Min. 1 M
ness around it
Large suction resistance of

fuel filter
Negative suction pressure
(Tank side)
27 kPa {203 mmHg}
20-580
1
ECMA
Voltage
Between 5 H
4.75 5.25 V
Between U H
0.42 0.58 V
D375A-5
TROUBLESHOOTING
SERVICE CODE EC554 (ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE

SENSOR SYSTEM)
Circuit diagram related to fuel rail pressure sensor
D375A-5
20-581
1
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF ELECTRICAL SYSTEM

(E-MODE)
Information in troubleshooting table .........................................................................................................

E-1 The engine does not start ................................................................................................................
E-2 Preheat does not operate (Manual preheating function) ..................................................................
E-3 The ripper pin puller cylinder does not operate ................................................................................
E-4 When the starting switch is on, none of the monitor panels come on ..............................................
E-5 When the starting switch is on, all the monitor panels are kept coming on and do not come out ............
E-6 When the starting switch is on, the basic check item flashes ..........................................................
E-7 When the engine is operating, the caution item flashes ..................................................................
E-8 When the engine is operating, the emergency alarm item flashes ..................................................
E-9 The preheating lamp does not come on ..........................................................................................
E-10 The display of the engine water temperature gauge is not normal ................................................
E-11 The display of the torque converter oil temperature gauge is not normal ......................................
E-12 The display of the fuel gauge is not normal ...................................................................................
E-13 The display of the gear speed/engine speed/shift mode is not normal ..........................................
E-14 The display of the service meter is not normal ..............................................................................
E-15 The switch module cannot be operated .........................................................................................
E-16 The alarm lamp does not flash or come out ...................................................................................
E-17 The alarm buzzer does not sound or stop .....................................................................................
E-18 The alarm buzzer cannot be cancelled ..........................................................................................
E-19 The service mode cannot be selected ...........................................................................................
E-20 Back-up alarm does not sound ......................................................................................................
E-21 Instrument panel night lamp, headlamp, working lamp and rear lamp do not come on .................
E-22 Air conditioner does not operate ....................................................................................................
D375A-5
20-602
20-603
20-605
20-607
20-608
20- 609
20-610
20-611
20-613
20-616
20-617
20-618
20-619
20-620
20-620
20-622
20-623
20-624
20-625
20-626
20-627
20-628
20-632
20-601
1
TROUBLESHOOTING

Trouble
Trouble in machine
Cause
Standard value in normal state to judge possible causes
Remarks on judgment
<Troubles in harness>
Disconnection
Connector is connected imperfectly or harness is broken.
Short circuit with chassis ground
Harness which is not connected to chassis ground circuit is in contact with chassis ground circuit.
Short circuit with power source
Harness which is not connected to power source (24 V) circuit is in
contact with power source (24 V) circuit.
Short circuit
Independent harnesses are in contact with each other abnormally.
Possible causes

(Given numbers are reference numbers, which do not <Precautions for troubleshooting>
indicate priority)
1Method of indicating connector No. and handling of T-adapter
Insert or connect T-adapter as explained below for troubleshooting,
unless otherwise specified.
3
If connector No. has no marks of male and female, disconnect
connector and insert T-adapters in both male side and female
side.
If connector No. has marks of male and female, disconnect
connector and connect T-adapter to only male side or female side.
2Entry order of pin Nos. and handling of tester leads
Connect positive (+) lead and negative () lead of tester as explained below for troubleshooting, unless otherwise specified.
Connect positive (+) lead to pin No. or harness entered on front
4
side.
Connect negative () lead to pin No. or harness entered on rear
side.
Part of electric circuit diagram related to trouble

Connector No.: Indicates (Model Number of pins) and (Color).
Arrows (): Indicate rough location of connector in machine.
20-602
1
D375A-5
TROUBLESHOOTING
E-1 THE ENGINE DOES NOT START

Trouble
The engine does not start.

Because the neutral safety function is provided in the engine starting circuit, the engine can be started
only when the parking lever is in the lock position.
Related information
If the Monitor panel does not come on or the Operating sound of the battery relay is not heard when
the starting switch is ON, a main power system abnormality is assumed. So inspect it.
Cause
Possible causes
6
D375A-5

Battery voltage
Battery specific gravity
Insufficient battery capacity
Min. 24 V
Min. 1.26
Prepare the engine with the starting switch OFF and diagnose it
with the starting switch OFF as is.
Starting switch failure
Key (male)
Switch position
Resistance value
OFF
Min. 1 M
Between 5 and 3
START
Max. 1
with the engine start.
Neutral safety relay failure
If
the
engine is started by the engine starting operation by replacing
this relay with another relay with the starting switch OFF, the neutral
safety relay (NSF) is faulty.
Diode failure
D03 (female)
Resistance value
Between 1 and 2
Min. 1 M
with the starting switch ON.
Diode failure
Alternator
Voltage
Between R terminal and ground
Max. 1 V
Starter
Voltage
Power: Between B terminal
20 30 V
and ground
Starter failure
Charge: Between R terminal
(Internal fault)
Max. 1 V
and ground
Start:
Between C terminal
20 30 V
and ground
If each voltage of power, charge, or start is normal and the starter is
not turned, the starter is faulty.
Harness disconnection failure
Between the harnesses between key (female) Resistance
Max. 1
3 and NSF (female) 3
value
(Disconnection/connector
contact failure)
Between harnesses between NSF (female) 5 Resistance
Max. 1
and top and bottom starter C terminal
value
Between alternator R terminal and top and
bottom starter C terminal, between alternator
Harness hot short-circuiting R terminal and D03 (female) 2, between alfailure
ternator R terminal and S03 (female) 4, be(24 V circuit and contact)
tween alternator R terminal and CN1 (female) Voltage
Max. 1 V
4, and between harness and ground
(Note: If hot short-circuiting occurs, the charge
level lamp comes on when the starting switch
is ON.)
20-603
1
TROUBLESHOOTING
Engine start/charge-related circuit diagram
20-604
1
D375A-5
TROUBLESHOOTING
E-2 PREHEAT DOES NOT OPERATE (MANUAL PREHEATING FUNCTION)

Trouble
Preheat does not operate.

This troubleshooting describes the procedures when the electrical intake air heater mounting unit is
not heated (if only the preheating lamp does not come on, execute the diagnosis indicating that the
Preheating lamp does not come on.)
Related information Preheat includes the Automatic preheating function and the Manual preheating function. Even if
which function is operated, the preheating lamp comes on.
If the Monitor panel does not come on or No operating sound of the battery relay is heard when
the starting switch is ON, a main power system abnormality is assumed. So inspect it.
Cause
4
Possible causes
D375A-5

Starting switch failure
Key (male)
Switch position
Resistance value
OFF
Min. 1 M
Between 5 and 2
HEAT
Max. 1
If the fuse is damaged by fire, the possibility of a ground fault having
Fuse (FS4-4) failure
occurred in the circuit is great.
with HEAT.
Preheater relay failure
If the engine is preheated by the heat operation by replacing this relay
with the starting switch OFF, the preheater relay (RHR) is faulty.
with HEAT.
Preheater
Voltage
Power: Between power supHeater relay failure
ply terminal and
20 30 V
(Internal fault)
ground
Signal: Between signal termi20 30 V
nal and ground
If each voltage of power and signal is normal and no operation sound
is heard, the heater relay is faulty.
Electrical intake air heater
failure
Electrical intake air heater
Continuity
(Internal fault)
Between terminals
Continue
Between harnesses between FS4-5 exit and Resistance
Max. 1
value
Harness disconnection fail- RHR (female) 5
ure
Between RHR (female) 3 and key (female)
Resistance
Max. 1
2, and between harnesses RHR (female) 3
value
contact failure)
and heater relay
Between harnesses between battery relay M
Resistance
terminal and starter and between the batter
Max. 1
value
relay M terminal and heater relay
Harness ground fault
(GND circuit and contact)
Between FS4-5 (exit side)-related harnesses Resistance
Min. 1 M
and between grounds
value
20-605
1
TROUBLESHOOTING
Engine preheat-related circuit diagram
20-606
1
D375A-5
TROUBLESHOOTING
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE

Trouble
The ripper pin puller cylinder does not operates.
Related information
Cause
1 Fuse (FS4-1) failure
Pin puller switch failure
2 (Internal disconnection/short
circuit)
Pin puller solenoid failure

circuit)
Possible causes

4
contact failure)

Harness hot short-circuiting

6 failure
(24 V circuit and contact)

If the fuse is damaged by fire, the possibility of a ground fault having
occurred in the circuit is great.
263 (male)
Switch
Resistance value
Draw-in
Max. 1
Between 1 and 2
Pull-in
Min. 1 M
224 (male)
Resistance value
Between 1 and 2
10 80
Between 1 and groud
Min. 1 M
with the starting switch Off as is.
Between harnesses between FS4-1 exit and Resistance
Max. 1
263 (female) 1
value
Between harnesses between 263 (female) 2 Resistance
Max. 1
and 224 (female) 1
value
Max. 1
and ground
value
Between FS4-1 (exit side)-related harnesses Resistance
Min. 1 M
and between grounds
value
Between harness and ground between 263
Resistance
Min. 1 M
(female) 2 and 224 (female) 1
value
Between harness and ground between 263
Voltage
Max. 1 V
Ripper pin puller solenoid-related circuit diagram
D375A-5
20-607
1
TROUBLESHOOTING
E-4 WHEN THE STARTING SWITCH IS ON, NONE OF THE MONITOR PANELS
COME ON
E-4 WHEN THE STARTING SWITCH IS ON, NONE OF THE MONITOR PANELS COME ON
Trouble (1)
The caution module (gauge portion/lamp portion) does not come on.
Related information When the starting switch is ON, all the monitor panels come on for three seconds.
Cause
2
Possible causes
3

If the circuit breaker is disconnected, the possibility of a ground fault
Circuit breaker (CB2) failure
having occurred in the circuit is great.
Between harnesses between CN1 (female) 1 Resistance
Max. 1
value
(Disconnection/connection and CB2 exit
contact failure)
Resistance
Between harnesses between CN1 2 and
Max. 1
value
ground
Resistance
Between CB2 (exit side)-related harnesses
Min. 1 M
value
and between grounds
Monitor panel failure
(Caution module)
CN1
Voltage
Between 1 and 2
20 30 V
Trouble (2)
The tachometer module (tachometer portion/service meter portion) does not come on.
Related information When the starting switch is ON, all the monitor panels come on for three seconds.
Cause
Circuit breaker (CB2, CB6)
1
failure

2
contact failure)
Possible causes
20-608
1
Harness fault ground


(Tachometer module)

Between harnesses between S03 (female) 1 Resistance
Max. 1
value
and CB2 exit
Max. 1
value
and CB6 exit
Max. 1
value
and ground
Resistance
Min. 1 M
value
and between grounds
Resistance
Min. 1 M
value
and between grounds
CN1
Voltage
Between 1 and 2
20 30 V
Between 7 and 2
20 30 V
D375A-5
TROUBLESHOOTING
E-5 WHEN THE STARTING SWITCH IS ON, ALL THE MONITOR PANELS ARE
KEPT COMING ON AND DO NOT COME OUT
Monitor panel power supply-related circuit diagram
E-5 WHEN THE STARTING SWITCH IS ON, ALL THE MONITOR PANELS ARE KEPT COMING
ON AND DO NOT COME OUT
Trouble (1)
The caution module (gauge portion/lamp portion) does not come out.
Related information When the starting switch is ON, all the monitor panels come on for three seconds, they come out.
Cause
Possible causes
and standard valMonitor panel failure
ue in normal state 1 (Caution module)

Because the monitor panel is internally faulty, it cannot be diagnosed.
Trouble (2)
The tachometer module (tachometer portion/service meter portion) does not come out.
Related information When the starting switch is ON, all the monitor panels come on for three seconds, they come out.
Cause
Possible causes
1
ue in normal state
(Tachometer module)
D375A-5

20-609
1
TROUBLESHOOTING
E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES
E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES
Trouble
The radiator water level lamp flashes.
Related information The basic check item flashes when an abnormality is detected before the engine starts.
Cause
Radiator water level de1 crease
2
Possible causes
Radiator water level failure


3
contact failure)

(Caution module)

Because the radiator water level decrease is detected, inspect the radiator water level (the lamp flashes below the specified level).
405 (male)
Resistance value
At normal time
Max. 1
Between 1 and 2
At decreased time
Min. 1 M
Max. 1
value
and 405 (female) 1
Max. 1
value
and ground
CN1
Voltage
At normal time
Max. 1 V
Between 1 and 2
At decreased time
20 20 V
Radiator water level sensor-related circuit diagram
20-610
1
D375A-5
TROUBLESHOOTING
E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES

Trouble
The charge level lamp flashes.
Related information The caution item flashes if an abnormality is detected when the engine is operating.
Cause
2
Possible causes
3
D375A-5

starting the engine.
Alternator failure
(Insufficient power generaAlternator
Engine speed
Voltage
tion)
Between R terminal
Above intermediate
20 30 V
and ground
speed (half)
Harness disconnection fail- Prepare the engine with the starting switch OFF and diagnose it
ure
Max. 1
contact failure)
and alternator R terminal
value
Between CN1 4 and S03 (female) 4, Between CN1 (female) and alternator R terminal,
between CN1 (female) 4 and top and bottom
Resistance
starter R terminal, between CN1 (female) 4
Min. 1 M
value
and NGICN3 (female), between harness and
ground between CN1 (female) 4 and battery
relay BR terminal
CN1
Engine speed
Voltage
(Caution module)
Between 4 and
Above intermediate
20 30 V
ground
speed (half)
20-611
1
TROUBLESHOOTING
20-612
1
D375A-5
TROUBLESHOOTING
E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM

FLASHES
E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM FLASHES
Trouble (1)
The fuel temperature lamp flashes.

The emergency alarm item flashes if an abnormality is detected when the engine is operating and
Related information
sounds the alarm buzzer.
Cause
Fuel temperature rises ab1 normally
Possible causes
Fuel temperature sensor
and standard val2
system failure
ue in normal state
3

(Caution module)

Inspect the fuel temperature since abnormal increase of fuel temperature has been detected. (When fuel temperature exceeds the specified temperature: Lamp flashes.)
Execute the service codes [EC261], [EC263] and [EC265].
If there is an abnormality in Causes 1 and 2, a monitor panel failure is
assumed (because the monitor panel is internally faulty, it cannot be
diagnosed).
Trouble (2)
Engine oil pressure lamp flashes.

Related information
Cause
Engine oil pressure de1 crease
Possible causes
and standard val2 system failure
ue in normal state
(engine controller system)
3

(Caution module)

Because the engine oil pressure decrease is detected, inspect the engine oil pressure (below specified pressure: Lamp flashes).
Execute the service codes [EC135] [EC141], and [EC143].
If there is an abnormality in Causes 1 and 2, a monitor panel failure is
diagnosed).
Trouble (3)
The engine water temperature lamp flashes.

Related information
The engine water temperature lamp flashes/comes out being linked with the display of the engine water temperature gauge.
Cause
1 overheat
Possible causes
and standard val2 system failure
ue in normal state
(engine controller system)
D375A-5

(Caution module)

Because the engine water temperature overheat is detected, inspect
the engine oil pressure (above water temperature of 108C; Lamp
flashes)
Check the display of the engine water temperature gauge. If the display is not normal, execute the diagnosis indicating that the Display
of the engine water temperature gauge is not normal.
Engine water
Water temperature
Gauge segment
temperature
lamp
7th stage
108C
Flashes
6th stage
Approx. 108C
5th stage
Approx. 102C
4th stage
Approx. 98C
Comes out
3rd stage
Approx. 94C
2nd stage
Approx. 83C
1st stage
Approx. 70C
If there is no abnormality in Causes 1 and 2, a monitor panel failure is
diagnosed).
20-613
1
TROUBLESHOOTING

FLASHES
Trouble (4)
The torque converter oil temperature lamp flashes.

Related information
The torque converter oil temperature lamp flashes/comes out being linked with the display of the
torque converter oil temperature gauge.
Cause
Torque converter oil temper- Because the torque converter overheat is detected, inspect the torque
1 ature overheat
converter oil temperature (above water temperature of 130C; Lamp
flashes)
Check the display of the torque converter oil temperature gauge. If the
display is not normal, execute the diagnosis indicating that the Display of the torque converter oil temperature gauge is not normal.
Gauge segment
Oil temperature lamp
temperature
Possible causes
7th stage
130C
Flashes
and standard valTorque converter oil temper2
6th stage
Approx. 130C
ue in normal state
ature system failure
5th stage
Approx. 120C
4th stage
Approx. 116C
Comes out
3rd stage
Approx. 110C
2nd stage
Approx. 90C
1st stage
Approx. 50C
If there is no abnormality in Causes 1 and 2, a monitor panel failure is
3
(Caution module)
diagnosed).
20-614
1
D375A-5
TROUBLESHOOTING

FLASHES
Trouble (5)
The hydraulic oil temperature lamp flashes.

Related information
Cause
Abnormal hydraulic oil tem- Because the abnormal hydraulic oil temperature rise is detected, in1 perature rise
spect the hydraulic oil temperature
(Above specified temperature: Lamp flashes)
Hydraulic oil
452 (male)
Continuity
2 sensor failure
temperature
Max. 105C
No continuity
Between 1 and
Possible causes
ground
Min. 105C
Continue
and standard val Prepare the engine with the starting switch OFF and diagnose it
ue in normal state
3
Between harness and ground between CN1 Resistance
Min. 1 M
value
Hydraulic oil
CN1
Voltage
4
temperature
(Caution module)
Max. 105C
20 30 V
Between 8 and
ground
Min. 105C
Max. 1 V
Hydraulic oil temperature sensor-related circuit diagram
D375A-5
20-615
1
TROUBLESHOOTING
E-9 THE PREHEATING LAMP DOES NOT COME ON
E-9 THE PREHEATING LAMP DOES NOT COME ON

Trouble
The preheating lamp does not come on.

This troubleshooting describes the procedures when the preheating lamp does not come on (if the
electrical intake air heater mounting portion is not heated, execute the diagnosis indicating that the
Related information Preheat lamp does not operate.
Preheat includes the Automatic preheat function and the Manual preheat function. Even if which
function operates, the preheating lamp comes on.
Cause
1
contact failure)
Possible causes
and standard val- 2 (GND circuit and contact)
ue in normal state

(Caution module)

Max. 1
value
and heater relay terminal
Min. 1 M
value
(female) 5 and heater relay terminal
CN2
Starting switch
Voltage
ON
Max. 1 V
Between 5 and
ground
HEAT
20 30 V
Engine preheat-related circuit diagram
20-616
1
D375A-5
TROUBLESHOOTING
E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT

NORMAL
E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT NORMAL
Trouble
The display of the engine water temperature gauge is nor normal.

The signal of the engine water temperature gauge is received by the communication from the engine
Related information
controller.
Possible causes
Cause
1 system failure
2
D375A-5

(Caution module)

Execute the diagnosis of the service codes [EC144] and [EC145].
If there is an abnormality in Cause 1, a monitor panel abnormality is
diagnosed).
20-617
1
E-11 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE

GAUGE IS NOT NORMAL
TROUBLESHOOTING
E-11 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT
NORMAL
Trouble
The display of the torque converter oil temperature gauge is not normal.
Related information
Cause

Torque converter oil temper453 (male)
Resistance value
temperature
ature sensor failure
1
(Internal disconnection/short
Approx. 80 k
Between 1 and 2
circuit)
approx. 3.8 k
10 100C
Between 1 and
Min. 1 M
ground
2
Max. 1
value
and 453 (female) 1
contact failure)
Possible causes
Max. 1
and standard valvalue
and ground
ue in normal state
3
Min. 1 M
value
4 failure
Between harness and ground beytween CN2
Voltage Max. 1 V
5
CN2 (female)
Resistance value
(Caution module)
temperature
Between 2 and
Approx. 80 k
10 100C
ground
approx. 3.8 k
Torque converter oil temperature-related circuit diagram
20-618
1
D375A-5
TROUBLESHOOTING
E-12 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL
E-12 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL

Trouble
The display of the fuel gauge is not normal.
Related information
Cause

Fuel level sensor failure
423 (male)
Remaining fuel level
Resistance value
circuit)
Full
Max. approx. 12
Between 1 and 2
(ground)
Empty
Approx. 85 110
Prepare
the
engine
with
the
starting
switch
OFF
and diagnose it
Harness disconnection failwith the starting switch OFF as is.
ure
2
Max. 1
contact failure)
and 423 (female) 1
value
Possible causes
and standard valwith the starting switch OFF as is.
ue in normal state 3 (GND circuit and contact)
Min. 1 M
value
4 failure
Between
harness and ground between CN2
Voltage
Max. 1 V
CN2 (female)
Remaining fuel level
Resistance value
5
(Caution module)
Full
Max. approx. 12
Between 3 and
ground
Empty
Approx. 85 110
Fuel level sensor-related circuit diagram
D375A-5
20-619
1
TROUBLESHOOTING
E-13 THE DISPLAY OF THE GEAR SPEED/ENGINE SPEED/SHIFT

IS NOT NORMAL
E-13 THE DISPLAY OF THE GEAR SPEED/ENGINEMODE
SPEED/SHIFT
MODE IS
E-14 THE DISPLAY OF THE SERVICE METER IS NOT NORMAL
E-13 THE DISPLAY OF THE GEAR SPEED/ENGINE SPEED/SHIFT MODE IS NOT NORMAL
Trouble
The display of the gear speed/engine speed/shift mode is not normal.

The signal of the gear speed/engine speed/shift mode is received by the communication from the
Related information
transmission controller and steering copntroller.
Cause
Possible causes
1
ue in normal state
(Tachometer module)


Trouble (1)
When the engine is operating, the time of the service meter does not run too fast.
Clock the time of the service meter using an engine operating signal (alternator voltage/engine oil
Related information
pressure).
Cause
1 Alternator system failure
2 system failure
Possible causes
Harness disconnection failand standard valure
ue in normal state 3
contact failure)

(Tachometer module)

If the charge level lamp flashes when the engine is operating, execute
the diagnosis indicating that the Caution item flashes when the engine is operating.
If the engine oil pressure lamp flashes when the engine is operating,
execute the diagnosis indicating that the Emergency alarm item
flashes when the engine is operating.
Max. 1
value
and circuit merging point
S03
Engine speed
Voltage
Between 4 and
Above intermediate
20 30 V
ground
speed (half)
Trouble (2)
The service meter is not displayed fully.
Related information
Cause
Possible causes
1
ue in normal state
(Tachometer module)
20-620
1

D375A-5
TROUBLESHOOTING
D375A-5
20-621
1
TROUBLESHOOTING
E-15 THE SWITCH MODULE CANNOT BE OPERATED
E-15 THE SWITCH MODULE CANNOT BE OPERATED

Trouble (1)
Even if the switch is operated, the lamp is not switched.
Related information
Cause
Possible causes
ue in normal state 1 (Switch module)

Trouble (2)
Even if the switch is operated, the system setting is not switched.
Related information The signal of the switch module is sent to each controller by communication.
Cause
Possible causes

1
contact failure)
2

(Switch module)

Between harnesses between S013 (female) Resistance
Max. 1
value
8 and circuit merging point
S01
Voltage
Between 8 and ground
69V
S-NET communication-related circuit diagram
20-622
1
D375A-5
TROUBLESHOOTING
E-16 THE ALARM LAMP DOES NOT FLASH OR COME OUT
E-16 THE ALARM LAMP DOES NOT FLASH OR COME OUT

Trouble
The alarm lamp does not flash or come out.

If a short circuit occurs in the alarm lamp system, a service code is displayed. In other failures, any
Related information
service code cannot be displayed.
Cause
Possible causes
3

Alarm lamp failure
375 (male)
Resistance value
circuit)
Between 1 and 2
100 400
Min. 1 M
Harness disconnection failBetween harnesses between CN2 (female) 7 Resistance
ure
Max. 1
and 375 (female) 2
value
contact failure)
Max. 1
and CB2 exit
value
Resistance
Min. 1 M
and grounds
value
CN2
Alarm lamp
Voltage
(Caution module)
Coming
out
20
30 V
Between 7 and
ground
Coming on
Max. 6 V
Alarm lamp-related circuit diagram
D375A-5
20-623
1
TROUBLESHOOTING
E-17 THE ALARM BUZZER DOES NOT SOUND OR STOP
E-17 THE ALARM BUZZER DOES NOT SOUND OR STOP

Trouble
The alarm buzzer does not sound or stop.

If a short circuit occurs in the alarm lamp system, a service code is displayed. In other failures, any
Related information
service code cannot be displayed.
Cause
Possible causes
3

Alarm lamp failure
217 (male)
Resistance value
circuit)
Between 1 and 2
200
Min. 1 M
Harness disconnection failBetween harnesses between CN2 (female) 8 Resistance
ure
Max. 1
value
and 217 (female) 1
contact failure)
Max. 1
value
and CB2 exit
Resistance
Min. 1 M
value
and grounds
CN2
Alarm buzzer
Voltage
(Caution module)
At stoppage time
20 30 V
Between 8 and
At operating
ground
Max. 3 V
(sounding) time
Alarm buzzer-related circuit diagram
20-624
1
D375A-5
TROUBLESHOOTING
E-18 THE ALARM BUZZER CANNOT BE CANCELLED
E-18 THE ALARM BUZZER CANNOT BE CANCELLED

Trouble
The alarm buzzer cannot be cancelled.
Related information
Cause
Possible causes

Buzzer cancel switch failure
212 (male)
Resistance value
OFF
Min. 1 M
Between 1 and 2
Between 1 and 3
ON
Max. 1
Between
harnesses between NGICN2 Z and Resistance
Harness disconnection failMax. 1
212 (female) 1
value
ure
Max. 1
contact failure)
and ground
value
Max. 1
and ground
value
Resistance
Between harness and ground between
Min. 1 M
value
NGICN Z and 212 (female) 1
NGICN2
Voltage
Steering controller failure
OFF
20 30 V
Between Z and
ground
ON
Max. 1 V
Buzzer cancel switch-related circuit diagram
D375A-5
20-625
1
TROUBLESHOOTING
E-19 THE SERVICE MODE CANNOT BE SELECTED
E-19 THE SERVICE MODE CANNOT BE SELECTED

Trouble
The service mode cannot be selected.
Related information
Cause
2
Possible causes

Set the starting switch to OFF for preparation and troubleshoot
while keeping the switch OFF.
Defective service switch
S24
Switch
Resistance value
OFF
Min. 1 M
Between 1 and 3
Between 4 and 6
ON
Max. 1
while keeping the switch OFF.
Resistance
Harness between S03 (female) 5 and S24 3
Max. 1
value
Disconnection of harness
Resistance
(Disconnection, defective
Max. 1
Harness between S24 1 and ground
value
contact of connector)
Harness between NG1CN1 (female) 6 and Resistance
Max. 1
S24 6
value
Resistance
Max. 1
Harness between S24 5 and ground
value
Set the starting switch to OFF for preparation and set the switch to
ON for troubleshooting.
S03
Service switch
Voltage
(Tachometer module)
OFF
20 30 V
Between 5 and
ground
ON
Max. 1 V
Set the starting switch to OFF for preparation and set the switch to
ON for troubleshooting.
NGICN1
Service switch
Voltage
Defective steering controller
OFF
20
30 V
Between 6 and
ground
ON
Max. 1 V
The buzzer cancel switch
The buzzer cancel switch system is supposed to be defective. Execute
system is defective
the troubleshooting of Alarm buzzer cannot be cancelled.
Circuit diagram related to service switch
20-626
1
(5)
D375A-5
TROUBLESHOOTING
E-20 BACK-UP ALARM DOES NOT SOUND
E-20 BACK-UP ALARM DOES NOT SOUND

Trouble
The back-up alarm does not sound.

When a failure occurs on the primary side (coil side) of the back-up alarm relay, a service code is disRelated information played, but in case of a failure on the secondary side (contact side), no service code cannot be displayed.
Cause
1 Defective fuse (FS4-1)
Defective back alarm relay

Possible causes
and standard val- 3 (Disconnection, defective
ue in normal state
Ground fault of harness

(contact with GND circuit)
Defective back-up alarm

(internal defect)

When the fuse is blown, there is a high possibility that the circuit was
short-circuited with ground.
Set the starting switch to OFF for preparation and set to ON for troubleshooting.
Replace this relay with another relay while the starting switch is set to
OFF, set the starting switch to ON and reverse this machine. If the
back-up alarm sounds, the back-up alarm relay (BKA) is defective.
while keeping it to OFF.
Harness between FS4-1 outlet and BKA (fe- Resistance
Max. 1
male) 3
value
Harness between BKA (female) 5 and 244 Resistance
Max. 1
(female) 2
value
Resistance
Harness between 244 (female) 1 and ground
Max. 1
value
Between harness (between FS4-1 outlet and Resistance
Min. 1 M
BKA (female) 3) and ground
value
Between harness (between BKA (female) 5 Resistance
Min. 1 M
and 244 (female) 2) and ground
value
When Causes 1 to 4 are not applicable, the back-up alarm is supposed to be defective.
D375A-5
20-627
1
TROUBLESHOOTING
E-21 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND

REAR LAMP DO NOT COME ON
E-21 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND REAR
LAMP DO NOT COME ON
Trouble (1)
Any of the instrument panel night lamp, headlamp, working lamp and rear lamp do not come on.
Related information
Cause
1 Defective fuse (FS2-5)
2 (Disconnection, defective
Possible causes
3


Harness between FS2-5 (outlet side) and cir- Resistance
Max. 1
value
cuit branched portion
Resistance
Between harness related to FS2-5 (outlet
Min. 1 M
value
side) and ground
Between harnesses (between 219 (female) 3
and CN4 (female) 1, between 219 (female)
3 and S03 (female) 1, between 219 (female) Resistance
Min. 1 M
value
3 and S02 (female) 1, between 219 (female)
3 and S01 (female) @ and between 219 (female) 3 and BB1 (female) 1) and ground
Between harnesses (between 218 (female) 3
Resistance
Min. 1 M
and 223 (female) 1 and between 218 (fevalue
male) 3 and 243 (female) 1) and ground
Trouble (2)
Any of the instrument panel night lamp, headlamp, working lamp and rear lamp do not come on.
Related information
Cause

Headlamp and working lamp
219 (male)
Switch
Resistance value
1 switches
OFF
Min. 1 M
Between 2 and 3
ON
Max. 1
Set
the
starting
switch
to
OFF
for
preparation
and
troubleshoot
Possible causes
and standard valHarness
between 219 (female) 2 and circuit Resistance
ue in normal state
Max. 1
value
branched portion
Harnesses between 219 (female) 3 and BB1
Resistance
(female) 1 and between 219 (female) 3 and
Max. 1
value
BB3 (female) 1
Harnesses between BB1 (female) 2 and
Resistance
ground and between BB3 (female) 2 and
Max. 1
value
ground
20-628
1
D375A-5
TROUBLESHOOTING

Trouble (3)
Only the instrument panel night lamp does not come on.
Related information
Cause
Defective night lamp
1
(Burnt bulb)
Possible causes

(Switch module)

(Tachometer module)

(Caution module)

The night lamp is supposed to be defective. Check if the light bulb is
burned out.
Set the starting switch to OFF for preparation Resistance
Max. 1
value
and troubleshoot while keeping it to OFF.
Harness between S01 (female) 8 and circuit Resistance
Max. 1
branched portion
value
Max. 1
branched portion
value
Resistance
Harness between S02 (female) 2 and ground
Max. 1
value
Max. 1
branched portion
value
Harness between CN4 (female) 1 and circuit Resistance
Max. 1
branched portion
value
Resistance
Harness between S04 (female) 2 and ground
Max. 1
value
Set the starting switch to OFF for preparation and set it to ON for
troubleshooting.
Between S01 @ and 2
Between S01 1 and 2
Light switch ON
20 30 V
troubleshooting.
Between S03 6 and 2
Light switch ON
20 30 V
troubleshooting.
Between CN4 1 and 2
Light switch ON
20 30 V
Trouble (4)
Only the headlamp does not come on.
Related information
Cause
Defective headlamp
1
(Burnt bulb)
2
(CB5)
3
Possible causes
D375A-5
Defective headlamp relay



The headlamp is supposed to be defective. Check if the light bulb is
burned out.
When the circuit breaker is cut off, there is a high possibility that the
circuit was short-circuited with ground.
troubleshooting.
When the starting switch is set to OFF, replace the relay with another
relay. Set the starting switch to ON and set the light switch to ON. If
the headlamp comes on, the headlamp relay (BB1) is defective.
Harness between CB5 outlet and BB1 (feResistance
Max. 1
male) 3
value
Harnesses between BB1 (female) 5 and 203
Resistance
Max. 1
(female) 1 and between BB1 (female) 5 and
value
204 (female) 1
Between harness related to CB5 (outlet side) Resistance
Min. 1 M
and ground
value
Between harnesses (between BB1 (female)
Resistance
5 and 203 (female) 1, between BB1 (female)
Min. 1 M
value
5 and 204 (female) 1) and ground
20-629
1
TROUBLESHOOTING

Trouble (5)
Only the working lamp does not come on. (Both right and left, or one side only)
Related information
Cause
Defective working lamp
1
(Burnt bulb)
2
Possible causes

The working lamp is supposed to be defective. Check if the light bulb
is burned out.
Defective fuse (FS2-4)
troubleshooting.
Defective working lamp relay
When the starting switch is set to OFF, replace the relay with another
relay. Set the starting switch to ON and set the light switch to ON. If
the working lamp comes on, the working lamp relay (BB3) is defective.
Harness between FS2-4 outlet and BB3 (fe- Resistance
Max. 1
value
male) 3
(Disconnection, defective
Harnesses between BB3 (female) 5 and 221
Resistance
(female) 1 and between BB3 (female) 5 and
Max. 1
value
241 (female) 1
Resistance
Between harness related to FS2-4 (outlet
Min. 1 M
value
side) and ground
Between harnesses (between BB3 (female)
Resistance
5 and 221 (female) 1, between BB3 (female)
Min. 1 M
value
5 and 241 (female) 1) and ground
Trouble (6)
Only the rear lamp does not come on. (Both right and left, or one side only)
Related information
Cause
Defective rear lamp
1
(Burnt bulb)
2
Possible causes
Defective rear lamp switch

20-630
1

The rear lamp is supposed to be defective. Check if the light bulb is
burned out.
troubleshooting.
218 (male)
Switch
Resistance value
OFF
Min. 1 M
Between 2 and 3
ON
Max. 1
Harness between 18 (female) 2 and circuit Resistance
Max. 1
value
branched portion
Harnesses between 218 (female) 3 and 223
Resistance
(female) 1 and between 218 (female) 3 and
Max. 1
value
243 (female) 1
D375A-5
TROUBLESHOOTING

Circuit diagram related to instrument panel night lamp, headlamp, working lamp and rear lamp
D375A-5
20-631
1
TROUBLESHOOTING
E-22 AIR CONDITIONER DOES NOT OPERATE

Trouble (1)
No airflow occurs
Related information
Cause
1
(CB4)

When the circuit breaker is cut off, there is a high possibility that the
circuit was short-circuited with ground.
Defective blower main relay
2
CN-R1 (male)
Resistance value
(coil side)
Between (1) and (2)
240 40
troubleshooting.
Defective blower main relay
3
CN-R1
Voltage
(contact side)
Between (6C) and ground
20 30 V
Defective blower Hi relay
4
CN-R2 (male)
Resistance value
(coil side)
Between (1) and (2)
240 40
troubleshooting.
Defective blower Hi relay
5
(contact side)
Set the starting switch to ON and set the blower Hi switch to ON. If the
motor rotates, the relay is normal.
Defective blower Mi relay
6
CN-R3 (male)
Resistance value
(coil side)
Between (1) and (2)
240 40
troubleshooting.
Defective blower Mi relay
7
(contact side)
Set the starting switch to ON and set the blower Mi switch to ON. If the
Possible causes
and standard valtroubleshooting.
ue in normal state 8 Defective blower motor
Set the starting switch to ON and set the blower Lo switch to ON. If the
Harness between CR-R3 (female) (0B), CNResistance
Max. 1
AC1 (female) (0C), CN-R (female) (0D) or
value
CCN-R2 (female) (0E) and ground
Harness between CN-B (female) (10A) and Resistance
Max. 1
value
CN-R (female) (10B)
Harnesses between CN-B (female) (11A) and
Resistance
CN-R2 (female) (11B) and between CN-B (feMax. 1
value
male) (11A) and CN-R (female) (11C)
Harnesses between CB4 outlet and CNAC1
(female) (13C), between CB4 outlet and CN9 (Disconnection, defective
Resistance
Max. 1
R1 (female) (13D), between CB4 outlet and
value
CN-R2 (female) (13E) and between CB4 outlet and CN-R3 (female) (13H)
Harness between CN-R1 (female) (14A) and Resistance
Max. 1
value
CN-AC1 (female) (14B)
Max. 1
value
Max. 1
value
When cases 1 to 9 are not applicable, the control panel is supposed to be
10 Defective control panel
defective.
Mistake of failure phenome- When any specific cause cannot be determined, failure phenomena might
11
non
have been mistaken. Execute the troubleshooting of No cooling.
20-632
1
D375A-5
TROUBLESHOOTING
Trouble (2)
No cooling
Related information
Cause
1 Defective pressure switch
Defective compressor clutch

2 relay
(coil side)
Defective compressor clutch
3 relay
(contact side)
Condenser relay
(contact side)
5 Defective thermistor
Defective condenser blower

resistor
Possible causes
and standard value in normal state 7 Defective condenser motor
8
Defective compressor magnet clutch
9 Defective compressor
11 Defective control panel
D375A-5

troubleshooting.
CN-P
Blower switch
Voltage
Between (26A) and
ON
20 30 V
ground
CN-R4 (male)
Resistance value
Between (1) and (2)
240 40
troubleshooting.
CN-R4
Voltage
Between (9B) and ground
20 30 V
troubleshooting.
CN-R5
Voltage
Between (7B) and ground
20 30 V
CN-AC1 (male)
Resistance value
Between (15B) and (16C)
Max. 3,500
Condenser blower resistor
Resistance value
Between terminals
2.8 5%
Set the starting switch to ON for troubleshooting.
Set the air conditioner switch to ON. If the motor rotates, it is normal.
Start the engine for troubleshooting.
The compressor magnet clutch is supposed to be defective. Check it
directly.
The compressor is supposed to be defective. Check it directly.
Harnesses between CB4 outlet and CN-R5
Resistance
(female) (6B) and between CB4 outlet and
Max. 1
value
CN-R4 (female) (6D)
Harness between CN-R5 (female) (7B) and Resistance
Max. 1
ARC (female) 2
value
Harness between CN-R4 (female) (9B) and Resistance
Max. 1
351 (female) 1
value
Harnesses between CB4 outlet and CN-R4 Resistance
Max. 1
(female) (131)
value
Harness between CN-T (female) (15A) and
Resistance
Max. 1
value
Harness between CN-P (female) (19A) and Resistance
Max. 1
CN-R4 (female) (19C)
value
Harness between CN-P (female) (26A) and Resistance
Max. 1
value
Harness between ARC (female) 1 and
Resistance
Max. 1
ground
value
When cases 1 to 10 are not applicable, the control panel is supposed
to be defective.
20-633
1
TROUBLESHOOTING
Circuit diagram related to air conditioner
20-634
1
D375A-5
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF
HYDRAULIC AND MECHANICAL SYSTEM
(H-MODE)
Information in troubleshooting table .........................................................................................................
H-1 No force (No drawbar pull) ...............................................................................................................
H-2 No travel (At 2nd or 3rd speed) ........................................................................................................
H-3 No travel at all gear speeds .............................................................................................................
H-4 Large time lag at gear speed shifting or forward-reverse shifting ....................................................
H-5 Large time lag at gear speed shifting or forward-reverse shifting ....................................................
H-6 Steering is not possible ....................................................................................................................
H-7 Steering is possible only on one side ..............................................................................................
H-8 Steering overrun occurs ...................................................................................................................
H-9 Brake does not work ........................................................................................................................
H-10 Torque converter is not lock-up ......................................................................................................
H-11 Torque converter oil is overheated .................................................................................................
H-12 All work equipment operates slowly ...............................................................................................
H-13 All work equipment does not operate ............................................................................................
H-14 Blade lift raising speed is slow or the blade lift has no power ........................................................
H-15 Blade tilt raising speed is slow or the blade tilt has no power ........................................................
H-16 Ripper lift raising speed is slow or the ripper lift has no power ......................................................
H-17 Ripper tilting speed is slow or the blade tilt has no power .............................................................
H-18 Hydraulic drift of blade lift is large ..................................................................................................
H-19 Hydraulic drift of blade tilt is large ..................................................................................................
H-20 Hydraulic drift of ripper lift is large .................................................................................................
H-21 Ripper pin puller cylinder does not operate ...................................................................................
H-22 Blade pitch does not operate .........................................................................................................
H-23 Abnormal noise occurs around the work equipment pump ............................................................
D375A-5
20-702
20-703
20-704
20-705
20-706
20-707
20-708
20-708
20-709
20-709
20-710
20-710
20-711
20-712
20-713
20-713
20-714
20-714
20-715
20-715
20-716
20-716
20-717
20-717
20-701
1
TROUBLESHOOTING

Trouble
Trouble in machine
Cause
Possible causes

(Given numbers are refer Standard value in normal state to judge possible causes
ence numbers, which do not
Remarks on judgment
indicate priority)
20-702
1
D375A-5
TROUBLESHOOTING
H-1 NO FORCE (NO DRAWBAR PULL)
H-1 NO FORCE (NO DRAWBAR PULL)

Trouble
No force (No drawbar pull)
Related information Before troubleshooting, check that the power train oil level is normal.
Cause
1 Defective power train pump The power train pump is supposed to be defective. Check it directly.
Set the starting switch to OFF for preparation and idle the engine at
a high speed for troubleshooting (after checking that the transmission main relief pressure is normal).
Internal defect of torque con2
Torque converter
Torque converter
verter
PCCS lever
inlet pressure
outlet pressure
39.2 63.7 MPa
0.8 1.0 MPa
Full neutral
{4.0 6.5 kg/cm2}
{8.0 10.0 kg/cm2}
Incorrect pressure set to
a high speed for troubleshooting.
3 transmission main relief
PCCS lever
valve
2.45 2.94 MPa {25.0 30.0 kg/cm2}
Full neutral
Defective operation of trans- while keeping it to OFF.
4
mission main relief valve
Check it directly that the spring free length (120.3 mm) is normal and
that the spool moves smoothly.
a low speed for troubleshooting (after checking that the transmission main relief pressure is normal).
Transmission clutch
Clutch pressure
Defective operation of trans2.35
2.94
MPa {24.0 30.0 kg/cm2}
FWD
5
mission valve (ECMV)
2.35 2.94 MPa {24.0 30.0 kg/cm2}
REV
1.96 2.55 MPa {20.0 26.0 kg/cm2}
1ST
Possible causes
2.35 2.94 MPa {24.0 30.0 kg/cm2}
2ND
and standard val2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD
ue in normal state
Internal defect of transmisMeasuring conditions
Engine speed
6
sion
F3 stall
1,430 rpm
F3 stall + Work equipment relief
1,160 rpm
Move the machine to a flat ground and start the engine for troubleshooting.
Defective operation (drag7
Idle the engine at a low speed and operate F2. Unless the machine
ging) of brake
moves, the brake is being dragged. (Execute the troubleshooting of
Brake does not work.)
PCCS lever
Left stroke end
Right stroke end
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
8 Defective steering clutch
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
Left brake pressure
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
When the oil pressure is abnormal, execute the troubleshooting of
Steering is not possible.
D375A-5
20-703
1
4
TROUBLESHOOTING
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)

Trouble
No travel (at 2nd or 3rd speed)

Before troubleshooting, check that the power train oil level is normal.
Related information
Before troubleshooting, check that the transmission main relief pressure is normal. (See H-1.)
Cause
3
4
Possible causes
5
20-704
1
4

Torque converter
Torque converter
Internal defect of torque conPCCS lever
inlet pressure
outlet pressure
verter
0.8 1.0 MPa
39.2 63.7 MPa
Full neutral
{8.0 10.0 kg/cm2}
{4.0 6.5 kg/cm2}
a low speed for troubleshooting.
Defective operation of transTransmission clutch
Clutch pressure
2.35
2.94
MPa {24.0 30.0 kg/cm2}
2ND
2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD
Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed
sion clutch
to be defective. Check it directly.
Defective operation (dragDefective operation (dragging) is supposed, check linkage valves.
ging) of parking brake
Defective operation (dragIdle
the engine at a low speed and operate F2. Unless the machine
ging) of brake
PCCS lever
Left stroke end
Right stroke end
Min. 2.4 MPa
0
{Min. 24 kg/cm2}
{0}
0
Min. 2.4 MPa
Defective steering clutch,
{0}
{Min. 24 kg/cm2}
brake
0
Min. 2.4 MPa
Left brake pressure
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
When the oil pressure is abnormal, execute the troubleshooting of
D375A-5
TROUBLESHOOTING
H-3 NO TRAVEL AT ALL GEAR SPEEDS
H-3 NO TRAVEL AT ALL GEAR SPEEDS

Trouble
No travel at all gear speeds
Cause
PCCS lever
valve
2.45 2.94 MPa {25.0 30.0 kg/cm2}
Full neutral
3
Transmission clutch
Clutch pressure
2.94
MPa {24.0 30.0 kg/cm2}
FWD
4
2.35 2.94 MPa {24.0 30.0 kg/cm2}
REV
1.96 2.55 MPa {20.0 26.0 kg/cm2}
1ST
2.35 2.94 MPa {24.0 30.0 kg/cm2}
2ND
2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD
Possible causes
Internal defect of transmis- The inside of transmission clutch (2nd speed, 3rd speed) is supposed
and standard val- 5 sion clutch
to be defective. Check it directly.
ue in normal state
Move the machine to a flat ground and idle the engine at a high
speed for troubleshooting (after checking that the transmission main
relief pressure is normal).
6 Defective operation of brake
Brake pedal
Brake oil pressure (right and left)
Release
Min. 2.4 MPa {Min. 24 kg/cm2}
Step on
0 {0}
PCCS lever
Left stroke end
Right stroke end
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
Defective seal of steering
7
clutch
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
Left brake pressure
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
Internal defect of steering
The inside of the steering clutch is supposed to be defective, check it
8
clutch
directly.
D375A-5
20-705
1
4
TROUBLESHOOTING
H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE

SHIFTING
H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING

Trouble
Large time lag at gear speed shifting or forward-reverse shifting
Cause
PCCS lever
2.45 2.94 MPa {25.0 30.0 kg/cm2}
Full
neutral
valve
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
3
a low speed for troubleshooting (after checking that the transmisPossible causes
sion main relief pressure is normal).
and standard valTransmission clutch
Clutch pressure
ue in normal state
2.94
MPa {24.0 30.0 kg/cm2}
FWD
4
2.35 2.94 MPa {24.0 30.0 kg/cm2}
REV
1.96 2.55 MPa {20.0 26.0 kg/cm2}
1ST
2.35 2.94 MPa {24.0 30.0 kg/cm2}
2ND
2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD
Defective seal of transmis- When the cause 4 is not applicable, the clutch seal is supposed to be
5
sion clutch
defective. Check it directly.
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
6
sion clutch
check it directly.
ging) of brake
20-706
1
D375A-5
TROUBLESHOOTING
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE

SHIFTING
H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING

Trouble
Large time lag at gear speed shifting or forward-reverse shifting
Cause
PCCS lever
Defective operation of trans2
2.45 2.94 MPa {25.0 30.0 kg/cm2}
Full neutral
When the oil pressure is abnormal, clean the valve and then check the
oil pressure again.
Transmission clutch
Clutch pressure
Possible causes
2.94
MPa {24.0 30.0 kg/cm2}
FWD
and standard val- 3 mission valve (ECMV)
2.35 2.94 MPa {24.0 30.0 kg/cm2}
REV
ue in normal state
1.96 2.55 MPa {20.0 26.0 kg/cm2}
1ST
2.35 2.94 MPa {24.0 30.0 kg/cm2}
2ND
2.35 2.94 MPa {24.0 30.0 kg/cm2}
3RD
Defective seal of transmis- When the cause 3 is not applicable, the clutch seal is supposed to be
4
sion clutch
Internal defect of transmis- The inside of the transmission clutch is supposed to be defective,
5
sion clutch
check it directly.
ging) of brake
D375A-5
20-707
1
H-6 STEERING IS NOT POSSIBLE

H-7 STEERING H-6
IS POSSIBLE
ONLY
ONPOSSIBLE
ONE SIDE
STEERING
IS NOT
TROUBLESHOOTING
H-6 STEERING IS NOT POSSIBLE

Trouble

Related information
Cause
Possible causes
and standard value in normal state 2
3
4

Start the engine for preparation and idle it at a low speed for troubleshooting.
Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for
F3 travel (or R3 travel). If the track shoe stops, the brake is defective.
(Execute the troubleshooting of Brake does not work.)
PCCS lever
Left stroke end
Right stroke end
Min. 2.4 MPa
0
{Min. 24 kg/cm2}
{0}
Defective operation of steer0
Min. 2.4 MPa
ing clutch valve (ECMV)
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
Left brake pressure
{0}
{Min. 24 kg/cm2}
Min. 2.4 MPa
0
{Min. 24 kg/cm2}
{0}
When the cause 2 is not applicable, the clutch seal is supposed to be
clutch
clutch
directly.
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE

Trouble
Steering is possible only on one side.

Related information
Cause

PCCS lever
Left stroke end
Right stroke end
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
ing clutch valve (ECMV)
Possible causes
{0}
{Min. 24 kg/cm2}
and standard val0
Min. 2.4 MPa
ue in normal state
Left brake pressure
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
When the cause 1 is not applicable, the clutch seal is supposed to be
2
clutch
3
clutch
directly.
20-708
1
4
D375A-5
H-8 STEERING OVERRUN OCCURS

H-9 BRAKE
DOES NOT
WORK
H-8 STEERING
OVERRUN
OCCURS
TROUBLESHOOTING
H-8 STEERING OVERRUN OCCURS

Trouble
Steering overrun occurs.

Related information
Cause

Start the engine for preparation and idle it at a low speed for troubleshooting.
Possible causes
1 Defective operation of brake Lift the machine with the blade and the ripper and steer the wheel for
and standard valF3 travel (or R3 travel). If the track shoe stops, the brake is defective.
ue in normal state
(Execute the troubleshooting of Brake does not work.)
When the track shoe does not stop in the troubleshooting of the cause
1, the steering clutch is defective. (Execute the troubleshooting of
ing clutch
Steering is not possible.)
H-9 BRAKE DOES NOT WORK

Trouble
Brake does not work.

Related information
Cause
Possible causes
3
4
5
D375A-5

Step on the brake pedal, shift the gear to F2 and idle the engine at a
Degradation of brake
high speed. When the machine moves, the brake performance is degraded.
Defective operation of brake The brake pedal and the brake valve are supposed not to work norpedal
mally. Check them directly.
PCCS lever
Left stroke end
Right stroke end
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
Min. 2.4 MPa
ing brake valve (ECMV)
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
Left brake pressure
{0}
{Min. 24 kg/cm2}
0
Min. 2.4 MPa
{0}
{Min. 24 kg/cm2}
When the brake seal is not normal in the troubleshooting of the cause
Defective brake seal
3, the brake seal is supposed to be defective. Check it directly.
Internal defect of brake
The inside of the brake is supposed to be defective. Check it directly.
20-709
1
4
H-10 TORQUE CONVERTER IS NOT LOCK-UP

H-11H-10
TORQUE
CONVERTER
OIL IS OVERHEATED
TORQUE
CONVERTER
NOT LOCK-UP
TROUBLESHOOTING
H-10 TORQUE CONVERTER IS NOT LOCK-UP

Trouble
The torque converter is not lock-up.

Related information
Cause
Defective operation of
2 torque converter lock-up
Torque converter
Clutch pressure
valve
Min. 1.27 1.47 MPa
At lock-up time
{Min. 13.0 15.0 kg/cm2}
Possible causes
Defective seal of lock-up
When the troubleshooting of the case 2 is not normal, the lock-up
and standard val- 3
clutch
clutch seal is supposed to be defective. Check it directly.
ue in normal state
Internal defect of lock-up
The inside of the lock-up clutch is supposed to be defective. Check it
4
clutch
directly.
Internal defect of torque conMeasuring conditions
Engine speed
5
verter
F3 stall
1,430 rpm
F3 stall + Work equipment relief
1,160 rpm
H-11 TORQUE CONVERTER OIL IS OVERHEATED

Trouble
The torque converter oil is overheated.

Before troubleshooting, check that the indication of the torque converter oil temperature gauge agrees
with actual temperature of the torque converter oil. (When the indication does not agree with actual
Related information
temperature, execute the troubleshooting of The indication of torque converter oil temperature gauge
is abnormal.)
Cause
1 Rise of engine output
Possible causes
20-710
1
Defective power train pump

or air entry in suction circuit
Internal defect of torque converter
Defective operation (slide) of

transmission clutch
Defective operation (dragging) of brake
Defective operation (slide) of

steering clutch

Engine output is supposed to have increased abnormally. Troubleshoot referring to the shop manual for engine.
The power train pump is supposed to be defective, or air is supposed
to have entered from the suction circuit. Check them directly.
Torque converter
Torque converter
PCCS lever
inlet pressure
outlet pressure
39.2 63.7 MPa
0.8 1.0 MPa
Full neutral
{4.0 6.5 kg/cm2}
{8.0 10.0 kg/cm2}
The inside of the transmission clutch is supposed to be defective (the
clutch slides). Check it directly.
The inside of the steering clutch is supposed to be defective (the
clutch slides). Check it directly.
D375A-5
TROUBLESHOOTING
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY

Trouble
All work equipment operates slowly.
Related information Before troubleshooting, check that the hydraulic tank oil level is normal.
1
2
3
4
5
6
Possible causes
7
10
11
D375A-5
Cause
Defective PTO (work equipment pump drive)
large pump
small pump
Defective PPC charge pump

The work equipment pump drive of the PTO is supposed to be defective. Check it directly.
The work equipment large pump is supposed to be defective. Check
it directly.
The work equipment small pump is supposed to be defective. Check
it directly.
The PPC charge pump is supposed to be defective. Check it directly.
Improper pressure set to
main relief valve for blade lift
Blade lever
valve
Raise
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
valve for blade lift valve
main relief valve for blade tilt
Blade lever
ripper Lo valve
Raise
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is supvalve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
charge relief valve
Work equipment lever
Control relief pressure
Full neutral
Min. 3.9 MPa {Min. 40.0 kg/cm2}
Internal defect of charge re- The inside of the charge relief valve is supposed to be defective.
lief valve
Check it directly.
Internal leak of PPC valve
Internal leak of PPC valve is supposed. Check it directly.
20-711
1
TROUBLESHOOTING
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE

Trouble
All work equipment does not operate.
Related information Before troubleshooting, check that the hydraulic tank oil level is normal.
1
2
3
4
5
Possible causes
10
11
20-712
1
Cause
Defective PTO (work equipment pump drive)
large pump
small pump
Defective PPC charge pump

The work equipment pump drive of the PTO is supposed to be defective. Check it directly.
The work equipment large pump is supposed to be defective. Check
it directly.
The work equipment small pump is supposed to be defective. Check
it directly.
The PPC charge pump is supposed to be defective. Check it directly.
main relief valve for blade lift
Blade lever
valve
Raise
Internal defect of main relief The inside of the main relief valve for blade lift valve is supposed to be
valve for blade lift valve
main relief valve for blade tilt
Blade lever
ripper Lo valve
Raise
Internal defect of main relief
The inside of the main relief valve for blade tilt ripper Lo valve is supvalve for blade tilt ripper Lo
posed to be defective. Check it directly.
valve
Work equipment lever
Control relief pressure
charge relief valve
Full neutral
Min. 3.9 MPa {Min. 40.0 kg/cm2}
Internal defect of charge re- The inside of the charge relief valve is supposed to be defective.
lief valve
Check it directly.
Defective operation of PPC The PPC lock valve is supposed to operate abnormally. Check the lelock valve
ver linkage or the lock valve directly.
D375A-5
TROUBLESHOOTING
H-14 BLADE
RAISING
SPEED IS
SLOWIS
OR
THE OR
BLADE
HASLIFT
NO HAS
POWER
H-14 LIFT
BLADE
LIFT RAISING
SPEED
SLOW
THELIFT
BLADE
NO
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER
Trouble
Related information
Blade lift raising speed is slow or the blade lift has no power.
Before troubleshooting, check that the hydraulic tank oil level is normal.
Check if the blade has been modified.
In case of large hydraulic drift of the blade lift, execute the troubleshooting of Hydraulic drift of blade
lift is large.
Cause
Possible causes
2
3

Defective operation of PPC
valve
Blade lever
Raising stroke end
Defective operation of blade The spool of the blade lift control valve is suppose to operate abnorlift control valve (spool)
mally. Check it directly.
The suction valve of the blade lift control valve is suppose to operate
Defective operation of blade abnormally. Check it directly.
lift control valve
It is also acceptable to replace the suction valve on the head side
(suction valve)
with the one on the bottom side to check change of the phenomenon as another method.
Air is supposed to enter the blade lift cylinder. Bleed air and check the
Air entry in blade lift cylinder
change of phenomenon.
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
Trouble
Related information
Blade tilt raising speed is slow or the blade tilt has no power.
lift is large.
Cause

1
Blade lever
valve
Possible causes
and standard valTilt stroke end
ue in normal state
Defective operation of blade The spool of the blade tilt control valve is suppose to operate abnor2
tilt control valve (spool)
mally. Check it directly.
Air is supposed to enter the blade tilt cylinder. Bleed air and check the
3 Air entry in blade tilt cylinder
D375A-5
20-713
1
TROUBLESHOOTING
H-16 RIPPER
RAISING
SPEED IS
SLOWIS
OR
THE OR
RIPPER
HASLIFT
NO HAS
POWER
H-16 LIFT
RIPPER
LIFT RAISING
SPEED
SLOW
THE LIFT
RIPPER
NO
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER
Trouble
Related information
Ripper lift raising speed is slow or the ripper lift has no power.
Check if the ripper has been modified.
lift is large.
Cause

valve
Defective operation of ripper

Possible causes
2
lift control valve (spool)
lift control valve
3
(constant differential pressure valve)
4 Air entry in ripper lift cylinder

Ripper lever
Raising stroke end
The spool of the ripper lift control valve (Lo, Hi) is suppose to operate
abnormally. Check it directly.
The constant differential pressure valve of the ripper lift control valve
(Hi) is suppose to operate abnormally. Check it directly.
It is also acceptable to replace the constant differential pressure
valve on the head side with the one on the bottom side to check
change of the phenomenon as another method.
Air is supposed to enter the ripper lift cylinder. Bleed air and check the
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
Trouble
Ripper tilting speed is slow or the ripper has no power.

Related information
Cause
1

valve

Possible causes
2
tilt control valve (spool)
tilt control valve
3
(constant differential pressure valve)
4 Air entry in ripper tilt cylinder
20-714
1

Ripper lever
Tilt end
The spool of the ripper tilt control valve (Lo, Hi) is suppose to operate
abnormally. Check it directly.
The constant differential pressure valve of the ripper tilt control valve
(Hi) is suppose to operate abnormally. Check it directly.
It is also acceptable to replace the constant differential pressure
valve on the head side with the one on the bottom side to check
change of the phenomenon as another method.
Air is supposed to enter the ripper tilt cylinder. Bleed air and check the
D375A-5
H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE

H-19 HYDRAULIC DRIFT OF BLADE LIFT
TILT IS LARGE
H-18
TROUBLESHOOTING
H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE

Trouble
Hydraulic drift of the blade lift is large

Related information
Before troubleshooting, check that no oil leaks from the work equipment circuit.
Cause
Possible causes
Defective seal of blade lift
1
and standard valcontrol valve (spool)
ue in normal state

cylinder

Start the engine for preparation and stop it for troubleshooting.
Follow the procedures below for the troubleshooting. When the hydraulic drift speed becomes fast, the spool seal of the blade lift control
valve is defective:
1)Stretch the blade lift on the ground and push up the front of the machine.
2)Stop the engine and release the safety lock lever.
3)Move the blade lever to the lift lowering side, and check the phenomenon.
The seal of the blade lift cylinder is supposed to be defective. Check
it directly.
H-19 HYDRAULIC DRIFT OF BLADE TILT IS LARGE

Trouble
Hydraulic drift of the blade tilt is large

Related information
Cause
Possible causes
D375A-5
Defective seal of blade tilt

control valve (spool)
Defective seal of blade tilt

cylinder

Follow the procedures below for the troubleshooting. When the hydraulic drift speed becomes fast, the spool seal of the blade tilt control
valve is defective:
1)Stretch the blade tilt on the ground and push up the right side of the
machine.
3)Move the blade tilt to the right tilt side, and check the phenomenon.
Blade tilt cylinder
Leakage from cylinder
Right tilt stroke end
12 cc/min
20-715
1
H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE

H-21 RIPPER
PIN PULLERDRIFT
CYLINDER
DOES NOT
H-20 HYDRAULIC
OF RIPPER
LIFT OPERATE
IS LARGE
TROUBLESHOOTING
H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE

Trouble
Hydraulic drift of the ripper lift is large

Related information
Cause
Possible causes

control valve (spool)
Defective seal of ripper lift

cylinder

Follow the procedures below for the troubleshooting. When the hydraulic drift speed becomes fast, the spool seal of the ripper lift control
valve (Hi) is defective:
1)Stretch the ripper lift on the ground and push up the rear of the machine.
3)Move the ripper lever to the lift lowering side, and check the phenomenon.
Leakage from cylinder
Lowering stroke end
12 cc/min
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE

Trouble
Ripper pin puller cylinder does not operate.
Related information Before troubleshooting, check that transmission main relief pressure is normal.
Cause
Defective operation of pin

Possible causes
1
puller solenoid
2
20-716
1
Internal defect of pin puller

cylinder

Pin puller operating
Pin puller switch
Measuring position
pressure
Push-in
Cylinder bottom side
Min. 2.4 MPa
{Min. 24 kg/cm2}
Pull-in
Cylinder head side
The inside of the pin puller cylinder is supposed to be defective. Check
it directly.
D375A-5
TROUBLESHOOTING
H-22 BLADE PITCH DOES NOT OPERATE

H-23 ABNORMAL NOISE OCCURSH-22
AROUND
THE
WORK
EQUIPMENT
PUMP
BLADE
PITCH
DOES
NOT OPERATE
H-22 BLADE PITCH DOES NOT OPERATE

Trouble
Blade pitch does not operate.
Related information
Cause
Defective operation of blade Operate both the blade pitch and the blade tilt. When only the pitch opPossible causes
1 pitch selection solenoid
eration is not possible, the pitch selection solenoid valve is operating
and standard valvalve
abnormally.
ue in normal state
Operate both the blade pitch and the blade tilt. When both the pitch
Defective operation of blade
2
operation and the tilt operation are not possible, the pitch cylinder (tilt
pitch cylinder
cylinder) is operating abnormally.
H-23 ABNORMAL NOISE OCCURS AROUND THE WORK EQUIPMENT PUMP

Trouble
Abnormal noise occurs around the work equipment pump.
Related information Before troubleshooting, check that the oil level in the hydraulic tank is normal.
Cause
1 Improper oil is used
Clogging of hydraulic tank
2
strainer
Possible causes
and standard value in normal state 3 Air entry in suction circuit
4
D375A-5
Internal defect of work

equipment pump

Improper oil is supposed to be used. Check it directly.
The hydraulic tank strainer is supposed to be clogged. Check it directly.
Air is supposed to have entered the suction circuit of the work equipment pump. Check the piping directly.
The inside of the work equipment pump is supposed to be defective.
Check it directly.
20-717
1
TROUBLESHOOTING
20 TROUBLESHOOTING
TROUBLESHOOTING OF THE ENGINE BODY

(S-MODE)
Points to remember when troubleshooting ..............................................................................................

Method of using troubleshooting charts ...................................................................................................
S-1 Starting performance is poor (starting always takes time) .............................................................
S-2 Engine does not start .....................................................................................................................
1) Engine does not turn ................................................................................................................
2) Engine turns but no exhaust smoke comes out (fuel is not being injected) .............................
3) Exhaust smoke comes out but engine does not start (fuel is being injected) ...........................
S-3 Engine does not pick up smoothly (follow-up is poor) ....................................................................
S-4 Engine stops during operations ......................................................................................................
S-5 Engine does not rotate smoothly (hunting) .....................................................................................
S-6 Engine lacks output (or lacks power) ..............................................................................................
S-7 Exhaust smoke is black (incomplete combustion) ..........................................................................
S-8 Oil consumption is excessive (or exhaust smoke is blue) ..............................................................
S-9 Oil becomes contaminated quickly .................................................................................................
S-10 Fuel consumption is excessive .......................................................................................................
S-11 Oil is in cooling water, or water spurts back, or water level goes down ..........................................
S-12 Oil pressure caution lamp lights up (drop in oil pressure) ..............................................................
S-13 Oil level rises ..................................................................................................................................
S-14 Water temperature becomes too high (overheating) ......................................................................
S-15 Abnormal noise is made .................................................................................................................
S-16 Vibration is excessive .....................................................................................................................
D375A-5
20-802
20-803
20-806
20-809
20-809
20-810
20-812
20-814
20-816
20-818
20-820
20-822
20-824
20-825
20-826
20-827
20-828
20-829
20-830
20-831
20-832
20-801
(5)
TROUBLESHOOTING

k
k
k
k
k
k
Stop the machine in a level place, and check that the safety pins and blocks are securely fitted, and the parking brake is securely applied.
When carrying out the operation with two or more workers, keep strictly to the agreed signals, and do not
allow any unauthorized person to come near.
If the radiator cap is removed when the engine is still hot, boiling water may spurt out and cause serious
burns. Always wait for the water temperature to go down before removing the radiator cap.
Be extremely careful not to touch any hot parts or to get caught in any rotating parts.
When disconnecting wiring, always disconnect the negative () terminal of the battery first.
When removing a plug or cap from a location which is under pressure from oil, water, or air, always release
the internal pressure first. When installing measuring equipment, be sure to connect it properly.
The aim of troubleshooting is to pinpoint the basic cause of the failure, to carry out repairs swiftly, and to prevent
reoccurrence of the failure. When carrying out troubleshooting, and important point is of course to understand
the structure and function. However, a short cut to effective troubleshooting is to ask the operator various questions to form some idea of possible causes of the failure that would produce the reported symptoms.
1. When carrying out troubleshooting, do not
hurry to disassemble the components
If components are disassembled immediately
any failure occurs:
Parts that have no connection with the failure
or other unnecessary parts will be disassembled.
It will become impossible to find the cause of
the failure.
It will also cause a waste of man-hours, parts, or
oil or grease, and at the same time, will also lose
the confidence of the user or operator.
For this reason, when carrying out troubleshooting, it is necessary to carry out thorough prior investigation and to carry out troubleshooting in
accordance with the fixed procedure.
2. Points to ask user or operator
1) Have any other problems occurred apart
from the problem that has been reported?
2) Was there anything strange about the machine before the failure occurred?
3) Did the failure occur suddenly, or were there
problems with the machine condition before
this?
4) Under what conditions did the failure occur?
5) Had any repairs been carried out before the
failure? When were these repairs carried
out?
6) Has the same kind of failure occurred before?
3. Checks before troubleshooting

1) Is there any sign of abnormality in the machine or engine?
2) Always carry out the Checks before starting.
3) Carry out other checks if necessary.
4) Other maintenance items can be checked
externally, so check any item that is considered to be necessary.
5) Check for any error display on the controller.
4. Confirming failure
Confirm the extent of the failure yourself, and
judge whether to handle it as a real failure or as
a problem with the method of operation, etc.
a When operating the machine to re-enact the
troubleshooting symptoms, do not carry out
any investigation or measurement that may
make the problem worse.
5. Troubleshooting
Use the results of the investigation and inspection in Items 2 4 to narrow down the causes of
failure, then use the troubleshooting matrix or
flowchart to locate the position of the failure exactly.
a The basic procedure for troubleshooting is
as follows.
1) Start from the simple points.
2) Start from the most likely points.
3) Investigate other related parts or information.
6. Measures to remove root cause of failure
Even if the failure is repaired, if the root cause of
the failure is not repaired, the same failure will
occur again.
To prevent this, always investigate why the problem occurred. Then, remove the root cause.
20-802
(5)
D375A-5
TROUBLESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS

This troubleshooting chart is divided into three sections: questions, check items, and troubleshooting. The questions and check items are used to
pinpoint high probability causes that can be located
from the failure symptoms or simple inspeciton without using troubleshooting tools.
Next, troubleshooting tools or direct inspection are
used to check the high probability causes to make final confirmation.
[Questions]
Sections A + B in the chart on the right corresponds to the items where answers can be obtained from the user. The items in B are items
that can be obtained from the user, depending
on the users level.
[Check items]
The serviceman carries out simple inspection to
narrow down the causes. The items under C in
the chart on the right correspond to this.
The serviceman narrows down the causes from
information A that he has obtained from the
user and the results of C that he has obtained
from his own inspection.
[Troubleshooting]
Troubleshooting is carried out in the order of
probability, starting with the causes that have
been marked as having the highest probability
from information gained from [Questions] and
[Check items].
The basic method of using the troubleshooting chart
is as follows.
Items listed for [Questions] and [Check items] that
have a relationship with the Cause items are marked
with Q, and of these, causes that have a high probability are marked with w.
Check each of the [Questions] and [Check items]
in turn, and marked the Q or w in the chart for items
where the problem appeared. The vertical column
(Causes) that has the highest number of points is the
most probable cause, so start troubleshooting for
that item to make final confirmation of the cause.
As a rule, do not use it when calculating the points
for locating the cause, but it can be included if necessary to determine the order for troubleshooting.
Use the E in the Cause column as reference for
[Degree of use (Operated for long period)] in the
[Questions] section as reference.
D375A-5
20-803
(5)
TROUBLESHOOTING
Example of troubleshooting when exhaust gas is black

Let us assume that [Clogged air cleaner] is taken to be the cause of black exhaust gas. Three symptoms
have causal relationship with this problem: [Exhaust gas slowly became black], [Power slowly became weaker], and [Dust indicator is red].
If we look from these three symptoms to find the causes, we find that there is a relationship with five causes.
Let us explain here the method of using this causal relationship to pinpoint the most probable cause.
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)

General causes why exhaust smoke is black
Insufficient intake of air
Defective condition of fuel injection
Excessive injection of fuel
20-804
(5)
D375A-5
TROUBLESHOOTING
Five causes
Step 1
Clarify the relationship between the three symptoms in
the [Questions] and [Check items] section and the five
Cause items in the vertical column.
Three symptoms
Step 2
Add up the total of
and
marks where the horizontal
limes for the three symptoms and the vertical columns for
the causes intersect.
(1) Clogged air cleaner element:
(2) Defective contact of valve, valve seat:
(3) Leakage of air between turbocharger
and head:
(4) Worn piston ring, cylinder liner:
(5) Defective timing rail pressure sensor:
Step 3
The calculation in Step 2 show that the closest
relationship is with [Worn piston ring, cylinder liner].
Follow this column down to the troubleshooting area and
carry out the troubleshooting item marked .
The Remedy is given as [Clean], so carry out cleaning,
and the exhaust gas color should return to normal.
D375A-5
20-805
(5)
TROUBLESHOOTING
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)

General causes why starting performance is poor
Defective electrical system
Insufficient supply of fuel
Improper selection of fuel
Defective HPI sensor
Defective HPI actuator
Defective fuel pump
Defective shut-off valve
Clogged timing rail actuator screen
Defective injector
Defective injector check ball
Cut, worn injector O-ring
Defective or deteriorated battery
Replace
Replace
Clean
Replace
Replace
Replace
Replace
Defective alternator regulator
Loose piping, fuel filter, entry of air

Clean
Defective alternator
Clogged fuel filter, strainer

Clean
Replace
Clogged fuel tank cap

Correct
Defective preheating circuit (when starting in low temperatures)
Worn piston ring, cylinder liner

Replace
Replace
Defective contact of valve, valve seat

Correct
Replace
Clogged air cleaner element

Clean
Causes
Confirm recent repair history

Degree of use of machine
Operated for long period
Questions
Starting performance became worse gradually

Engine starts easily when warm
Non-specified fuel is being used
Replacement of filters has not been carried out according to Operation Manual
Engine oil must be added more frequently
Charge caution lamp lights up
When preheating, preheating indicator lamp does not light up
Dust indicator is red
Air breather hole in fuel tank cap is clogged
Check items
Starting motor cranks engine slowly

When engine is
Little fuel comes out even when injection pump sleeve nut is loosened
cranked with
Little fuel comes out even when fuel filter air bleed plug is loosened
starting motor,
When exhaust manifold is touched immediately after starting engine, temperature
of some cylinders is low
Engine does not pick up smoothly, and combustion is irregular
There is hunting from engine (rotation is irregular)
Blow-by gas is excessive
Difficult to stop engine
Inspect air cleaner element directly
When compression pressure is measured, it is found to be low
Inspect fuel filter, strainer directly
When negative pressure at inlet port of fuel pump is measured, it is found to be high
When pressure at outlet port of fuel pump is measured, it is found to vary

When pressure at outlet port of fuel pump is measured, it is found to be low
Troubleshooting
Inspect fuel pump directly

Inspect fuel shut-off valve directly
Inspect timing rail actuator screen directly
When temperature of exhaust gas of each cylinder is measured, there are some
cylinders that are low
Inspect injector directly
When specific gravity of electrolyte and voltage of battery are measured, one of
them is low
When starting switch is turned to HEAT, heater mount does not become warm
Is voltage 26 - 30V between alternator terminal B and terminal E with
engine at low idling?
Yes
No
Inspect sensor directly (Output voltage and resistance)

Inspect actuator directly (Resistance and filter for clogging)
Remedy
20-806
(5)
D375A-5
TROUBLESHOOTING
Defective fuel rail pressure sensor
Defective timing rail pressure sensor
Defective fuel pump pressure sensor
Defective water temperature sensor
Defective intake manifold temperature sensor
Defective fuel rail actuator (Marked
Defective timing rail actuator (Marked
Defective fuel pump actuator (Marked
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
1)
1)
Defective boost pressure sensor

Replace
D375A-5
1)
Defective atmospheric pressure sensor

Replace
Causes
1. If the following service codes are displayed, carry out

the troubleshooting in Service code. (If any of the following service codes is not displayed, they are not
probably the cause of the trouble. In this case, inspect
the other devices for the cause.)
[EC514]: Abnormality in fuel rail actuator
[EC112]: Abnormality in timing rail actuator
[EC318]: Abnormality in fuel pump actuator
20-807
(5)
TROUBLESHOOTING
S-2 ENGINE DOES NOT START

1) Engine does not turn
Causes
Defective starting motor
Defective safety relay or safety switch

Replace
Replace
Defective starting switch
Replace
Defective battery terminal connection

Correct
Defective starting circuit wiring

Replace
Replace
Broken flywheel ring gear

Replace
General causes why engine does not turn

Internal parts of engine seized
a See Troubleshooting S-4.
Defective electrical system
Problem in power train (troubleshooting in chassis volume)
Questions

Condition of horn when starting

switch is turned ON
Horn does not sound

Horn volume is low
Battery electrolyte is low

Battery terminal is loose
When starting switch is turned to ON, there is no clicking sound from battery relay
Check items
When starting switch is turned to START, starting pinion does not move out
Speed of rotation is low
When starting switch is turned
to START, starting pinion moves
out, but
Makes grating noise

Soon disengages again
Makes rattling noise and does not turn
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When terminal B and terminal C of starting switch are connected, engine starts
Turn starting switch
OFF, connect cord,
and carry out
troubleshooting at
ON
There is no 24V between battery relay terminal B and terminal E

When terminal B and terminal C of starting motor are connected, engine starts
When terminal B and terminal C of safety relay are connected, engine starts
1.
Troubleshooting
Inspect flywheel ring gear directly
Remedy
When terminal of safety switch and terminal B of starting motor are connected, engine starts
1. Carry out troubleshooting in chassis volume
D375A-5
20-809
(5)
2) Engine turns but no exhaust smoke comes out (fuel is not being injected)
Broken fuel pump drive shaft
Replace
Replace

Clean
Clogged timing actuator screen

Clean
Replace

Correct
Defective fuel shut-off valve wiring
Insufficient fuel in tank

Add
General causes why engine turns but no exhaust smoke comes out
Fuel is not being supplied
Supply of fuel is extremely small
Improper selection of fuel (particularly in winter)
Replace
Causes
Replace
TROUBLESHOOTING
Questions

Exhaust smoke suddenly stopped coming out (when starting again)

Starts when engine is warm
When fuel tank is inspected, it is found to be empty
Rust and water are found when fuel tank is drained
Check items
When fuel filter is drained, fuel does not come out

There is leakage from fuel piping
Wiring of fuel shut-off valve is loose
Cylinder block ground wiring is loose
When engine is cranked with
starting motor, and
Fuel pump outlet port coupler is pushed, almost no fuel comes out
Fuel pump outlet port coupler is pushed, air comes out together with fuel
Troubleshooting

Inspect fuel pump drive shaft directly
Inspect fuel shut-off valve directly
When starting switch is turned to START, voltage [24V] is not generated between fuel shut-off valve connector
pins
Remedy
20-810
(5)
D375A-5
TROUBLESHOOTING
1)
1)
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
D375A-5
1)

Replace
Causes

20-811
(5)
3) Exhaust smoke comes out but engine does not start (fuel is being
injected)
Defective fuel pump
Clogged timing actuator screen
Clean
Replace
Replace
Defective preheating heater circuit

Clean

Clean
Correct

Replace
Defective injector
Defective dynamic valve system (valve, rocker arm, etc.)

Replace
Replace

Clean
General causes why exhaust smoke comes out but engine does not start
Lack of rotating force due to defective electrical system
Improper selection of fuel and oil
Causes
Replace
TROUBLESHOOTING

Questions
Suddenly failed to start

Starts when engine is warm
When preheating, preheating indicator lamp does not light up
Check items

When fuel filter is drained, no fuel comes out
Starting motor cranks engine slowly
When engine is cranked, abnormal noise is generated around cylinder head
When engine is
cranked with starting
motor, and
Inspect dynamic valve system directly
Troubleshooting
When fuel filter, strainer directly
When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
When specific gravity of electrolyte and voltage of battery are measured, one of them is low
When starting switch is at HEAT, heater mount does not become warm
Inspect fuel rail actuator directly
Remedy
20-812
(5)
D375A-5
D375A-5
1)

1)

Clogged fuel rail actuator
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Replace
1)
Replace
TROUBLESHOOTING
Causes

20-813
(5)
TROUBLESHOOTING
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)

General causes why engine does not pick up smoothly
Defective condition of fuel spray
Improper fuel used
Abnormality in fuel control system
Normal output is not applied
o See Troubleshooting S-6
Clean
Clean
Failure boost pressure sensor

Correct
Defective injector

Replace
Replace
Improper valve clearance

Correct
Defective fuel pump
Defective contact of valve and valve seat

Replace
Replace
Seized turbocharger
Correct
Replace

Clean
Causes
Questions
Engine pick-up suddenly became worse

Rust and water are found when fuel is drained
When engine is cranked
with starting motor, and
Check items
When exhaust manifold is touched immediately after starting engine, temperature of some cylinders is low
Color of exhaust gas
Blue under light load

Black
Clanging sound is heard from around cylinder head

Noise of interference is heard from around turbocharger
High idling speed under no load is normal, but speed suddenly drops when load is applied
When turbocharger is rotated by hand, it is found to be heavy
Troubleshooting
Inspect valve clearance directly

When temperature of injector of each cylinder is measured, there are some cylinders that are low
When intake air pressure (boost pressure) is measured, it is found to be normal
Inspect for air leakage
Remedy
20-814
(5)
D375A-5
TROUBLESHOOTING
Air leakage from piping between turbocharger and cylinder head
Replace
Replace
Replace
1)
1)

Replace
1)
Replace
Causes
D375A-5

20-815
(5)
TROUBLESHOOTING
S-4 ENGINE STOPS DURING OPERATIONS

General causes why engine stops during operations
Seized parts inside engine
There is overheating
Problem in power train (troubleshooting in chassis volume)
Broken fuel pump drive shaft
Defective injector
Correct
Correct
Clean
Replace
Replace
Broken, seized gear train
Add
Failure in power train (troubleshooting in chassis volume)
Broken, seized main bearing, connecting rod bearing
Replace
Broken auxiliary equipment (pump, compressor, etc.)
Broken, seized piston, connecting rod
Replace
Broken dynamic valve system (valve, rocker arm, etc.)
Replace
Causes


Abnormal noise was heard and engine stopped suddenly
Questions
Condition when engine stopped
Engine overheated and stopped

Engine stopped slowly
There was hunting and engine stopped

Fuel level caution lamp lights up
Metal particles are found when oil is drained
Check items
Does not turn at all

When it is attempted
to turn by hand using
barring tool
Turns in opposite direction

Moves amount of gear backlash
Fuel pump shaft does not turn

When engine is
motor, and
Engine turns, but stops when load is applied to machine
Inspect piston, connecting rod directly
Troubleshooting
Inspect main bearing, connecting rod directly

Inspect gear train directly
Engine rotates when pump auxiliary equipment (pump, compressor, etc.) is removed
1.
Replace
Replace
Remedy
Replace
20-816
(5)
D375A-5
TROUBLESHOOTING

Clogged fuel inlet circuit
Replace
Replace
Replace
Replace
Replace
Replace
Replace
Clean
1)

Replace
1)
1)
Causes
D375A-5
20-817
(5)
TROUBLESHOOTING
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)

General causes why engine does not rotate smoothly
Air in fuel system
Defective governor mechanism
Defective injector
Replace
High resistance, clogged fuel return circuit
Defective actuation of timing rail actuator

Replace
Defective actuation of fuel rail actuator

Replace
Clean
Defective fuel pump

Replace
Defective injector check ball

Clean
Replace

Clean
Replace

Replace
Causes

Questions

Occurs at a certain speed range
Condition of hunting
Occurs at low idling

Occurs even when speed is raised
Occurs on slopes

Rust, water are found when fuel tank is drained
Check items
Leakage from fuel piping

starting motor, and
Engine speed sometimes rises too far
Engine is difficult to stop
Troubleshooting
When flow of spill fuel is checked visually, it is found to be low
Inspect fuel rail actuator screen directly
Remedy
20-818
(5)
D375A-5
D375A-5
Clogged fuel rail actuator screen
Clogged timing rail actuator screen
Replace
Replace
Defective in speed sensor
Replace
Replace
Replace
Replace
Replace
Defective in throttle sensor
Replace
Replace
1)
TROUBLESHOOTING
Causes
1. If the following service code is displayed, carry out the

troubleshooting in Service code. (If it is not displayed,
it is not probably the cause of the trouble. In this case,
inspect the other devices for the cause.)
20-819
(5)
TROUBLESHOOTING
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
Defective injector
Replace
Replace
Replace
Defective fuel pump
Replace
Correct
Improper adjustment of valve clearance
Replace
Adjust
Clean
Seized turbocharger, interference
Replace
Clean
Replace
Causes
Clean
a Measure the engine speed and judge if the problem is in the engine
or on the machine.
General causes why engine lacks output
Improper fuel used
(if non-specified fuel is used, output drops)
There is overheating
Questions

Suddenly
Power was lost
Gradually

Dust indicator lamp is red
When engine is
motor, and
Check items
Black

Engine pickup is poor and combustion is irregular
High idling speed of engine is low
Troubleshooting


Check part No. of controller calibration data
Remedy
20-820
(5)
D375A-5
TROUBLESHOOTING
High resistance or clogged fuel circuit
Replace
Replace
Clean
Defective controller calibration data

Replace

Replace
Defective throttle sensor

Replace
D375A-5

Replace
1)

Replace
1)
1)
Causes

20-821
(5)
TROUBLESHOOTING

General causes why exhaust smoke is black
Seized turbocharger, interference
Improper adjustment of valve clearance
Leakage of air between turbocharger and cylinder head
Crushed, clogged muffler
Defective fuel pump
Defective injector
Replace
Replace
Adjust
Correct
Replace
Replace
Replace
Replace
Failure timing rail pressure sensor
Replace
Replace
Replace
1)

Clean
Causes


Suddenly became black
Questions
Gradually became black


Power was lost
Suddenly
Gradually

Muffler is crushed
Leakage of air between turbocharger and head, loose clamp
Check items

Exhaust noise is abnormal
Engine pickup is poor and combustion is irregular
Inspect air cleaner directly
Troubleshooting

When muffler is removed, exhaust sound improves
Inspect between turbocharger and cylinder head directly
Abnormality in timing rail pressure sensor system is indicated ( 2)
Inspect sensor directly (Output voltage)
Remedy
20-822
(5)
D375A-5
TROUBLESHOOTING

2. If a service code of the timing rail pressure sensor system is displayed, carry out the troubleshooting in Service code.
D375A-5
20-823
(5)
TROUBLESHOOTING
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)

a To prevent the oil from leaking up or down in the turbocharger,
do not run the engine at idling for more than 20 minutes continuously (both low and high idling).
General causes why oil consumption is excessive
Abnormal combustion of oil
External leakage of oil
Wear of parts in lubrication system
Broken oil cooler

Replace
Leakage from oil pan or cylinder head
Leakage from oil drain plug

Correct
Leakage from oil piping
Too much engine oil added

Correct
Correct
Worn, broken rear oil seal

Correct
Leakage from oil filter or oil cooler
Clogged breather or breather hose

Clean
Correct
Broken piston ring

Replace
Correct

Replace
Worn seal at blower end
Worn, damaged valve (stem, guide, seal)

Correct
Worn seal at turbine end
Turbocharger
Dust sucked in from intake system
Causes
Questions

Oil consumption suddenly increased

Engine oil becomes contaminated quickly
Oil level is above H level on gauge
Outside of engine is dirty with oil
There are loose piping clamps in intake system
Check items
Inside of turbocharger intake pipe is dirty with oil

Inside of exhaust pipe is dirty with oil
There is oil in engine cooling water
Oil level in clutch chamber or damper chamber rises
Exhaust smoke is blue under light load
Amount of blow-by gas
Excessive
None
Troubleshooting
When intake manifold is removed, dust is found inside

Excessive play of turbocharger shaft
When intake manifold is removed, inside is found to be dirty with oil
Inspect breather element directly
Inspect rear oil seal directly
There is external leakage of oil from engine
20-824
(5)
Replace
Replace
Remedy
Correct
Pressure-tightness test of oil cooler shows there is leakage
D375A-5
TROUBLESHOOTING
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-9 OIL BECOMES CONTAMINATED QUICKLY

General causes why oil becomes contaminated quickly
Entry of exhaust gas into oil due to internal wear
Clogging of lubrication passage
Defective combustion
Improper fuel used
Operation under excessive load
Oil change interval is too long
Defective seal at turbocharger turbine end
Worn valve (stem, guide, seal)
Clogged breather, breather tube
Too much engine oil added
Clogged oil cooler
Clogged oil filter
Defective oil filter safety valve
Replace
Replace
Replace
Clean
Correct
Clean
Replace
eplace
Exhaust smoke is black
Clogged turbocharger lubrication drain tube

Clean
Causes
Questions

Non-specified oil is being used

Oil level is above H level on gauge
When oil filter is inspected, metal particles are found
Check items
When exhaust pipe is removed, inside is found to be dirty with oil

Even when engine oil temperature rises, oil filter caution lamp lights up (machines equipped with caution lamp)
Engine oil temperature rises quickly

Amount of blow-by gas

Black
Excessive
None
Carry out
Troubleshooting S-7
Excessive play of turbocharger shaft

Inspect breather element directly
Inspect oil cooler directly
Inspect oil filter directly
Inspect safety valve directly
Remedy
D375A-5
Troubleshooting
Inspect turbocharger lubrication drain tube directly
20-825
(5)
TROUBLESHOOTING
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-10 FUEL CONSUMPTION IS EXCESSIVE

General causes why fuel consumption is excessive
Leakage of fuel
Failure timing rail pressure sensor

Replace
Failure fuel rail pressure sensor

Replace

Replace
Replace
Defective injector
Replace
High resistance, clogged fuel return circuit
Defective fuel pump

Replace
Replace

Clean
Clean
Leakage of fuel inside head cover

Correct
Causes

Questions

More than for other machines of same model
Condition of fuel consumption
Gradually increased
Suddenly increased
There is external leakage of fuel from engine
Check items
Engine oil level rises and smells of diesel fuel

starting motor, and
Exhaust smoke color
Black
White
Inspect inside of head cover directly

Troubleshooting
Abnormality in fuel rail pressure sensor system is indicated ( 1)
Abnormality in timing rail pressure sensor system is indicated ( 1)
When flow of return fuel is checked visually, it is found to be low
Inspect sensor directly (Output voltage)
1. If a service code of the fuel rail pressure sensor system or timing rail pressure sensor
system is displayed, carry out the troubleshooting in "Service code".
20-826
(5)
Remedy
D375A-5
TROUBLESHOOTING
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER

LEVEL GOES DOWN
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
General causes why oil is in cooling water
Internal leakage in lubrication system
Internal leakage in cooling system
Broken oil cooler core, O-ring

Replace
Broken power train oil cooler (troubleshooting in chassis volume)
Damaged cylinder liner O-ring, holes caused by pitting

Replace
Broken water pump seal
Insufficient protrusion of cylinder liner

Replace
Replace
Internal cracks in cylinder block

Replace
Replace
Broken cylinder head, head gasket

Replace
Causes
Questions

Oil level

Suddenly increased
Gradually increased
Troubleshooting
Check items
Hard water is being used as cooling water (or corrosion resistor valve is closed)
Excessive air bubbles inside radiator, spurts back
Engine oil level has risen, oil is cloudy white
Hydraulic oil, transmission oil on machine side is cloudy white
When hydraulic oil, transmission oil on machine side is drained, water is found
Carry out pressure-tightness test of cylinder head
Inspect cylinder block, liner directly
Inspect cylinder liner directly
Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Remedy
D375A-5
20-827
(5)
TROUBLESHOOTING
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)

General causes why oil pressure caution lamp lights up
Leakage, clogging, wear of lubricating system
Defective oil pressure control
Improper selection of fuel (insufficient viscosity)
Deterioration of oil due to overheating
Defective oil level sensor

Defective oil pressure sensor
Water, fuel in oil

Non-specified oil is being used
Engine oil pressure caution lamp lights up
Lights up at low idling

Lights up at low, high idling
Condition when oil pressure lamp lights up

Lights up on slopes

Sometimes lights up
Oil level caution lamp lights up (machines equipped with caution lamp)
There is crushing, external leakage from hydraulic piping
Oil level in oil pan is low
Oil is cloudy white or smells of diesel oil
When oil is drained, metal particles are found
When oil filter is inspected, metal particles are found
20-828
(5)
Replace
Replace
Remedy
Carry out Troubleshooting

S-13

Inspect suction strainer, pipe directly
Oil pump rotation is heavy, there is play
Inspect relief valve, regulator valve directly
When engine oil level sensor is replaced, oil pressure lamp goes out
(machines equipped with oil level sensor)
When oil pressure is measured, it is found to be normal
Clean
Add
Clean
Clean
Correct
Replace
Adjust
Replace
Clean
Correct
Troubleshooting
Check items
Questions
Worn crankshaft journal

Lack of oil in oil pan
Clogged oil pan suction strainer
Clogged, broken oil pump suction pipe
Broken oil pump suction pipe brazing
Defective oil pump
Defective oil pump relief valve
Clogged oil cooler
Clogged oil filter
Leaking, crushed hydraulic piping
Causes
D375A-5
TROUBLESHOOTING
S-13 OIL LEVEL RISES
S-13 OIL LEVEL RISES
Defective thermostat seal

Worn fuel pump seal
Defective auxiliary equipment (pump, compressor) seal
Broken aftercooler core

Defective cylinder head injector sleeve
Cracks inside cylinder block
Broken, broken rear oil seal face
Broken oil cooler core, O-ring
Clogged water pump drain hole (breather hole), defective seal
Causes

Fuel must be added more frequently
Engine oil smells of diesel fuel
There is oil in cooling water
When engine is first started, drops of water come from muffler
When radiator cap is removed and engine is run at low idling, an abnormal number of bubbles
appear, or water spurts back
Exhaust smoke is white
Water pump drain hole (breather hole) is clogged
When water pump drain hole (breather hole) is cleaned, water comes out
Oil level goes down in clutch or damper chamber
Oil level goes down in hydraulic tank
Carry out pressure-tightness test of aftercooler
Inspect rear oil seal directly
Carry out pressure-tightness test of oil cooler
Inspect water pump directly
Inspect thermostat directly
Inspect injector directly
Inspect pump auxiliary equipment (pump, compressor) directly
Remedy
D375A-5
Replace
Replace
Replace
Replace
Replace
Correct
Replace
Replace
Correct
Replace
Correct
Replace
Troubleshooting
Check items
Questions
a If there is oil in the cooling water, carry out Troubleshooting S-11.

General causes why oil level rises
Cooling water in oil (milky white)
Fuel in oil (diluted, and smells of diesel fuel)
Entry of water or oil from other component
20-829
(5)
TROUBLESHOOTING
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)

General causes why water temperature becomes too high
Lack of cooling air (deformation, damage of fan)
Drop in heat dissipation efficiency
Rise in oil temperature in power train
(troubleshooting in chassis volume)
Clogged, crushed radiator fins
Defective radiator cap (pressure valve)
Fan belt slipping, worn fan pulley
Broken water pump
Replace
Correct
Replace
Rise in power train oil temperature (troubleshooting in chassis volume)
Clogged radiator core
Correct
Defective water temperature gauge
Lack of cooling water
Correct
Defective operation of thermostat
Clogged, broken oil cooler
Add
Replace
Replace
Replace
Cracks inside cylinder block
Replace
Replace
Causes
Questions

Condition of overheating
Water temperature gauge

Suddenly overheated
Always tends to overheat
Rises quickly
Does not go down from red range
Radiator water level caution lamp lights up (machines equipped with caution lamp)
Engine oil level has risen, oil is cloudy white
Cloudy white oil is floating on cooling water
Excessive air bubbles inside radiator, water spurts back
Check items
When light bulb is held behind radiator, no light passes through

Radiator shroud, inside of underguard are clogged with dirt or mud
Water is leaking because of cracks in hose or loose clamps
When belt tension is inspected, it is found to be loose
Fan belt whines under sudden load
Cooling water flows out from overflow hose
Power train oil temperature enters red range faster than engine water temperature
Troubleshooting

Inspect oil cooler directly
Inspect radiator core directly
When temperature difference between top and bottom radiator tanks is measured, it is found to
be slight
Carry out function test on radiator cap (cracking pressure)
When temperature difference between top and bottom radiator tanks is measured, it is found to
be excessive
1.
Carry out function test on thermostat (cracking temperature)
Remedy
Replace
When water temperature is measured, it is found to be normal
20-830
(5)
D375A-5
TROUBLESHOOTING
S-15 ABNORMAL NOISE IS MADE
S-15 ABNORMAL NOISE IS MADE
Seized turbocharger, internal interference

Leakage of air between turbocharger and head
Broken dynamic valve system (valve, rocker arm, etc.)
Defective adjustment of valve clearance
Defect inside muffler (dividing board out of position)
Excessive wear of piston ring, cylinder liner
Seized crankshaft bearing
Missing, seized gear bushing
Improper gear train backlash
Deformed cooling fan, fan belt interference
Defective injector
Air leakage from auxiliary equipment (pump, compressor)
Causes


Gradually occurred
Condition of abnormal noise

Suddenly occurred
Seal on injection pump has come off
Metal particles are found in oil filter
Leakage of air between turbocharger and head, loose clamp
Vibrating noise is heard from around muffler


Black
Engine pickup is poor and combustion is abnormal
Abnormal noise is loud when accelerating engine

When muffler is removed, abnormal noise disappears
Inspect crankshaft bearing directly
Inspect front gear and rear gear directly
Inspect cooling fan, belt directly
When temperature of exhaust gas of each cylinder is measured, there are some cylinders that are low
Inspect piping of pump auxiliary equipment (pump, compressor, etc.) directly
Remedy
D375A-5
Replace
Correct
Replace
Adjust
Replace
Replace
Replace
Replace
Correct
Correct
Replace
Replace
Troubleshooting
Check items
Questions
a Judge if the noise is an internal noise or an external noise.

General causes why abnormal noise is made
Abnormality due to defective parts
Abnormal combustion noise
Air sucked in from intake system
20-831
(5)
TROUBLESHOOTING
S-16 VIBRATION IS EXCESSIVE
S-16 VIBRATION IS EXCESSIVE
Worn cam bushing
Improper gear train backlash
Defective vibration damper
Clogged injector
Worn front support spigot joint portion
Loose engine mounting bolts, broken cushion
Replace
Correct
Replace
Adjust
Replace
Replace
Replace
(troubleshooting for machine)
Worn main bearing, connecting rod

Replace
Internal damage in clutch chamber or damper chamber
Defective dynamic valve system (valve, rocker arm, etc. stuck)
Causes
Replace
a If there is abnormal noise together with the vibration, carry out Troubleshooting S-15 also.
General causes why vibration is excessive
Defective parts (abnormal wear, breakage)
Improper alignment between engine and chassis
Abnormal combustion
Questions

Condition of vibration

Suddenly increased
Gradually increased

Seal on injection pump has come off
Metal particles are found in oil filter
Check items
Metal particles are found when oil is drained

Oil pressure is low at low idling
Vibration occurs at mid-range speed
Vibration follows engine speed
Exhaust smoke is black
Troubleshooting
Inspect main bearing, connecting rod directly

Inspect cam bushing directly
Inspect front gear train and rear gear train directly
Inspect vibration damper directly
Injection pump test shows that injection amount is incorrect
Inspect front support spigot joint directly
Inspect engine mounting bolts, cushions directly
Remedy
20-832
(5)
Replace
Inspect clutch chamber or damper chamber directly (troubleshooting for machine)
D375A-5
30 DISASSEMBLY AND ASSEMBLY

DISASSEMBLY AND ASSEMBLY
30 DISASSEMBLY AND ASSEMBLY

HOW TO READ THIS MANUAL ................. 30- 5
Removal and installation of assemblies 30- 5
Disassembly and assembly of
assemblies ........................................... 30- 6
PRECAUTIONS WHEN CARRYING
OUT OPERATION ...................................... 30- 7
SPECIAL TOOL LIST ................................. 30- 8-1
SKETCHES OF SPECIAL TOOLS ............ 30-8-10
REMOVAL AND INSTALLATION OF
FUEL PUMP ASSEMBLY ........................... 30- 9
Removal ............................................... 30- 9
Installation ............................................. 30- 9
ENGINE FRONT SEAL .............................. 30- 10
Special tools ......................................... 30- 10
Removal ............................................... 30- 10
Installation ............................................. 30- 10
ENGINE REAR SEAL ................................. 30- 12
Special tools ......................................... 30- 12
Removal ............................................... 30- 12
Installation ............................................ 30- 12
CYLINDER HEAD ASSEMBLY .................. 30- 14
Special tools ......................................... 30- 14
Removal ............................................... 30- 14
Installation ............................................ 30- 17
FUEL TANK ASSEMBLY ............................ 30- 19
Removal ............................................... 30- 19
Installation ............................................ 30- 19
RADIATOR ASSEMBLY ............................ 30- 20
Removal ............................................... 30- 20
Installation ............................................ 30- 21
RADIATOR GUARD ASSEMBLY ............... 30- 22
Special tools ......................................... 30- 22
Removal ............................................... 30- 22
Installation ............................................ 30- 24
ENGINE ASSEMBLY .................................. 30- 25
Special tools ......................................... 30- 25
Removal ............................................... 30- 25
Installation ............................................. 30- 28
D375A-5

DAMPER ASSEMBLY .................................
Special tools ..........................................
Removal ................................................
Installation .............................................
DISASSEMBLY AND ASSEMBLY OF
DAMPER .....................................................
Disassembly of damper assembly ........
Disassembly of damper cover assembly
Assembly of damper assembly .............
Assembly of damper cover assembly ...
POWER TRAIN UNIT ASSEMBLY .............
Removal ................................................
Installation .............................................
DISCONNECTION OF
POWER TRAIN UNIT ASSEMBLY .............
CONNECTION OF POWER TRAIN UNIT
ASSEMBLY .................................................
PTO ASSEMBLY .......................................
Disassembly ..........................................
Assembly ..............................................
TORQUE CONVERTER ASSEMBLY .........
Special tools ..........................................
Disassembly ..........................................
Assembly ..............................................
TORQFLOW TRANSMISSION
ASSEMBLY .................................................
Special tools ..........................................
Disassembly ..........................................
Assembly ..............................................
STEERING CASE ASSEMBLY ..................
Disassembly ..........................................
Assembly ..............................................
POWER TRAIN, LUBRICATION
PUMP ASSEMBLY .....................................
Removal ................................................
Installation .............................................
30303030-
29
29
29
31
3030303030-
33
33
33
34
35
30- 36
30- 36
30- 39
30- 40
30- 45
30- 47
30- 47
30- 50
30303030-
54
54
54
58
30303030-
64
64
64
79
30- 96
30- 96
30-102
30- 113
30- 113
30- 113
30-1
2(7)c

SCAVENGING PUMP ASSEMBLY .............
Removal ................................................
Installation .............................................
FINAL DRIVE ASSEMBLY ..........................
Special tools ..........................................
Removal ................................................
Installation .............................................
FINAL DRIVE ASSEMBLY ..........................
Special tools ..........................................
Disassembly ..........................................
Assembly ..............................................
TRACK FRAME ASSEMBLY ......................
Removal ................................................
Installation .............................................
IDLER ASSEMBLY .....................................
Removal ................................................
Installation .............................................
IDLER ASSEMBLY ....................................
Special tools ..........................................
Disassembly ..........................................
Assembly ..............................................
Sketch of special tool ............................
RECOIL SPRING ASSEMBLY ....................
Special tools ..........................................
Removal ................................................
Installation .............................................
RECOIL SPRING ASSEMBLY ...................
Special tools ..........................................
Disassembly ..........................................
Assembly ..............................................
REMOVAL AND INSTALLATION
TRACK ROLLER ASSEMBLY .....................
Special tools ..........................................
Removal ................................................
Installation .............................................
TRACK ROLLER ASSEMBLY ....................
Special tools ..........................................
Disassembly ..........................................
Assembly ..............................................
BOGIE ASSEMBLY ....................................
Special tools ..........................................
Removal ................................................
Installation .............................................
30-2
"
2 "
30-114
30-114
30-114
30-115
30-115
30-115
30-115
30-116
30-116
30-116
30-122
30-131
30-131
30-132
30-133
30-133
30-133
30-134
30-134
30-134
30-135
30-138
30-139
30-139
30-139
30-142
30-143
30-143
30-143
30-144
30-145
30-145
30-145
30-146
30-148
30-149
30-149
30-149
30-150
30-152
30-153
30-153
30-153
30-155
30-158

BOGIE ASSEMBLY ..................................... 30-159
Special tools .......................................... 30-159
Disassembly .......................................... 30-159
Assembly ............................................... 30-160
1ST BOGIE ASSEMBLY ............................. 30-161
Special tools .......................................... 30-161
Removal ................................................ 30-161
Installation ............................................. 30-163
Sketch of special tool ............................ 30-166
EXPANDING AND ASSEMBLY TRACK
SHOE INSTALLATION ................................. 30-167
Check before expanding track
shoe assembly ...................................... 30-167
Expanding track shoe assembly ............ 30-168
Expanding track shoe assembly ............ 30-168
Installation of track shoe assembly ........ 30-169
WHOLE DISASSEMBLY AND ASSEMBLY
OF TRACK SHOE ....................................... 30-170
Special tools .......................................... 30-170
Whole disassembly ............................... 30-171
Whole assembly .................................... 30-173
1. When recycling for lubricated
track ................................................. 30-173
2. When recycling for greasefilled track ........................................ 30-182
DIMENSIONS TABLE OF FITTING
JIG OF LINK PRESS ................................... 30-187
1 LINK IN THE FIELD .................................. 30-188
Special tools .......................................... 30-188
Disassembly .......................................... 30-188
Assembly ............................................... 30-190
MASTER LINK ............................................. 30-192
Special tools .......................................... 30-192
Disassembly .......................................... 30-193
Assembly ............................................... 30-194
PIVOT SHAFT ASSEMBLY ......................... 30-197
Special tools .......................................... 30-197
Removal ................................................ 30-197
Installation ............................................. 30-197
EQUALIZER BAR ........................................ 30-199
Special tools .......................................... 30-199
Removal ................................................ 30-199
Installation ............................................. 30-201
EQUALIZER BAR BUSHING ...................... 30-202
Special tools .......................................... 30-202
Disassembly .......................................... 30-202
Assembly ............................................... 30-203
D375A-5

SEGMENT TOOTH ....................................
Removal ...............................................
Installation ............................................
HYDRAULIC TANK ASSEMBLY ................
Removal ...............................................
Installation ............................................
WORK EQUIPMENT AND PPC
PUMP ASSEMBLY .....................................
Removal ...............................................
Installation ............................................
BLADE LIFT VALVE ASSEMBLY ...............
Removal ...............................................
Installation ............................................
BLADE LIFT VALVE ASSEMBLY ...............
Assembly ..............................................
BLADE TILT AND RIPPER LOW
VALVE ASSEMBLY ....................................
Assembly ..............................................
RIPPER HIGH VALVE ASSEMBLY ...........
Assembly ..............................................
PPC CHARGE VALVE ASSEMBLY ...........
Assembly ..............................................
BLADE PPC VALVE ASSEMBLY ...............
Assembly ..............................................
RIPPER PPC VALVE ASSEMBLY .............
Assembly ..............................................
HYDRAULIC CYLINDER ASSEMBLY .......
Special tools .........................................
Disassembly .........................................
Assembly ..............................................
RIPPER PIN PULLER CYLINDER
ASSEMBLY ................................................
Special tools .........................................
Disassembly .........................................
Assembly ..............................................
BLADE ASSEMBLY ....................................
Removal ...............................................
Installation ............................................
BLADE ASSEMBLY ....................................
Disassembly .........................................
Assembly ..............................................
D375A-5
30-205
30-205
30-205
30-206
30-206
30-208
30-209
30-209
30-209
30-210
30-210
30-211
30-212
30-212
30-214
30-215
30-216
30-217
30-218
30-218

GIANT RIPPER ASSEMBLY ......................
Disassembly ..........................................
Assembly ..............................................
ROPS GUARD ............................................
Removal ................................................
Installation .............................................
OPERATOR'S CAB ASSEMBLY ................
Removal ................................................
Installation .............................................
FLOOR FRAME ..........................................
Special tools ..........................................
Removal ................................................
Installation .............................................
DASHBOARD ASSEMBLY .........................
Special tools ..........................................
Removal ................................................
Installation .............................................
MONITOR PANEL ASSEMBLY ...................
Removal ................................................
Installation .............................................
AIR CONDITIONER UNIT ASSEMBLY ......
Removal ................................................
Installation .............................................
30-237
30-237
30-238
30-240
30-240
30-240
30-241
30-241
30-242
30-243
30-243
30-243
30-246
30-248
30-248
30-248
30-249
30-250
30-250
30-250
30-251
30-251
30-253
30-219
30-219
30-221
30-221
30-222
30-222
30-222
30-225
30-228
30-228
30-228
30-229
30-231
30-231
30-232
30-233
30-233
30-235
30-3
2 "
"
HOW TO READ THIS MANUAL

ASSEMBLIES
Special tools
Special tools that are deemed necessary for removal or installation of parts are listed.
List of the special tools contains the following
kind of information.
1) Necessity
": Special tools which cannot be substituted, should always be used.
# Special tools which are very useful if
available, can be substituted with commercially available tools.
2) Distinction of new and existing special tools
N:
Tools with new part numbers, newly
developed for this model.
R:
Tools with upgraded part numbers, remodeled from already available tools
for other models.
Blanks: Tools already available for other
models, used without any modification.
3) Circle mark (!) in sketch column:
A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Installation of parts
Except where otherwise instructed, install parts
is the reverse order of removal.
Instructions and precautions for installing parts
are shown with q 1 mark in the INSTALLATION
Section, identifying which step the instructions
are intended for.
Marks shown in the INSTALLATION Section
stand for the following.
This mark indicates safety-related precautions which must be followed when

doing the work.
This mark gives guidance or precautions when doing the procedure.

2 This mark stands for a specific coating
agent to be used.
3 This mark indicates the specified
torque.
5
This mark indicates an amount of oil or

water to be added.
Sketches of special tools

Various special tools are illustrated for the convenience of local manufacture.
Removal of parts
The REMOVAL Section contains procedures,
precautions and the amount of oil or water to be
drained.
Various symbols used in the REMOVAL Section
are explained and listed below.

doing the work.
This mark gives guidance or precautions

when doing the procedure.
This mark shows that there are instrucq1
tions or precautions for installing parts.
This mark shows oil or water to be
6
drained.
4 Mass of a part or component.
D375A-5
30-5
2 !
4

ASSEMBLIES
Special tools
Special tools which are deemed ncessary for
disassembly and assembly are listed in this section.
List of the special tools contains the following
kind of information.
1) Neccessity
": Special tools which cannot be substituted, should always be used.
# Special tools which are very useful if
available, can be substituted with commercially available tools.
2) Distinction of new and existing special tools
N:
Tools with new part numbers, newly
developed for this model.
R:
Tools with upgraded part numbers, remodeled from already available tools
for other models.
Blanks: Tools already available for other
models, used without any modification.
3) Circle mark (!) in sketch column:
A circle mark means that a sketch of the special tool is presented in the section of Sketches for Special Tools.
Part No. of special tools starting with 79*T
means that they are locally made parts and as
such not interchangeable with those made by
Komatsu in Japan e.g. 79*T---xxx---xxxx.
Assembly
Section titled ASSEMBLY contain procedures,
precautions and the know-how for the work, as
well as the amount of oil or water to be added.
Various symbols used in the ASSEMBLY Section
are explained and listed below.

doing the work.
This mark gives guidance or precautions when doing the procedure.

2 This mark stands for a specific coating
agent to be used.
3 This mark indicates the specified
torque.
5
This mark indicates an amount of oil or

water to be added.
Sketches of special tools

Various special tools are illustrated for the convenience of local manufacture.
Disassembly
The DISASSEMBLY Section contains procedures, precautions and the amount of oil or water
to be drained.
Various symbols used in the DISASSEMBLY
Section are explained and listed below.

doing the work.
This mark gives guidance or precautions

when doing the procedure.
This mark shows that there are instrucq1
tions or precautions for installing parts.
6
This mark shows oil or water to be
drained.
4 Mass of a part or component.
30-6
!
2 !
4
D375A-5

OUT OPERATION
PRECAUTIONS WHEN CARRYING OUT OPERATION

[When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general precautions given below when carrying out the operation.]
1. Precautions when carrying out removal work
If the coolant contains antifreeze dispose of it correctly.

After disconnecting hoses or tubes, cover them or fit blind plugs to prevent dirt or dust from entering.
When draining oil, prepare a container of adequate size to catch the oil.
Confirm the match marks showing the installation position, and make match marks in the necessary places
before removal to prevent any mistake when assembling.
To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
Check the number of thickness of the shims, and keep in a safe place.
When raising components, be sure to use lifting equipment of ample strength.
When using forcing screws to remove any components, tighten the forcing screws uniformly in turn.
Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from entering
after removal.
Precautions when handling piping during disassembly

Fit the following blind plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
Plug (nut end)
Nut (elbow end)
02
07376-70210
02789-00210
03
07376-70315
02789-00315
04
07376-70422
02789-00422
05
07376-70522
02789-00522
06
07376-70628
02789-00628
2) Split flange type hoses and tubes

Nominal
number
Flange (hose end)
Sleeve head (tube end)
Split flange
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
number
Part Number
06
07049-00608
Dimensions (mm)
D
08
07049-00811
6.5
11
10
07049-01012
10
8.5
12
12
07049-01215
12
10
15
14
07049-01418
14
11.5
18
16
07049-01620
16
13.5
20
18
07049-01822
18
15
22
20
07049-02025
20
17
25
22
07049-02228
22
18.5
28
24
07049-02430
24
20
30
27
07049-02734
27
22.5
34
D375A-5
30-7
2 !
4

OUT OPERATION
2. Precautions when carrying out installation work
Tighten all bolts and nuts (sleeve nuts) to the specified (KES) torque.
Install the hoses without twisting or interference.
Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
Bend the cotter pins and lock plates securely.
When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion
with 2 - 3 drops of adhesive.
When coating with gasket sealant, clean the surface and remove all oil and grease, check that there is no
dirt or damage, then coat uniformly with gasket sealant.
Clean all parts, and correct any damage, dents, burrs, or rust.
Coat rotating parts and sliding parts with engine oil.
When press fitting parts, coat the surface with anti-friction compound (LM-P).
After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect securely.
When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align the
direction of the hook.
When tightening split flanges, tighten uniformly in turn to prevent excessive tightening on one side.
When operating the hydraulic cylinders for the first time after reassembling cylinders, pumps and other hydraulic equipment removed for repair, always bleed the air as follows:
1. Start the engine and run at low idling.
2. Operate the work equipment control lever to operate the hydraulic cylinder 4 - 5 times, stopping the cylinder 100 mm from the end of its stroke.
3. Next, operate the hydraulic cylinder 3 - 4 times to the end of its stroke.
4. After doing this, run the engine at normal speed.
When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing the operation
If the coolant has been drained, tighten the drain valve, and add water to the specified level. Run the engine
to circulate the water through the system. Then check the water level again.
If the hydraulic equipment has been removed and installed again, add engine oil to the specified level. Run
the engine to circulate the oil through the system. Then check the oil level again.
If the piping or hydraulic equipment has been removed, always bleed the air from the system after reassembling the parts. For details, see TESTING AND ADJUSTING, Bleeding air.
Add the specified amount of grease (molybdenum disulphide grease) to the work equipment parts.
30-8
"
2 "
D375A-5
DISA
SPECIAL TOOL LIST
SPECIAL TOOL LIST

Tools with part number 79!T-!!!-!!!! cannot be supplied (they are items to be locally manufactured).
Necessity: ": Cannot be substituted, should always be installed (used).
#: Extremely useful if available, can be substituted with commercially available part.
New/remodel: N: Tools with new part numbers, newly developed for this model.
R: Tools with upgraded part numbers, remodeled from items already available for other models.
Blank: Tools already available for other models, used without any modification.
Tools marked ! in the Sketch column are tools introduced in special sketches (See SKETCHES OF SPECIAL TOOLS).
Component
Symbol
1
2
A
Engine assembly
4
5
A
Torque converter
assembly
1
2
3
Torquflow transmission
assembly
D375A-5
Part No.
Part name
Nature work remarks
795-902-1410
Sleeve
"
01050-32240
Bolt
"
795-902-1430
Push tool
"
01050-32235
Bolt
"
795-902-1420
Sleeve
"
795-902-1450
Bolt
"
01582-02016
Nut
"
795-902-1440
Push tool
"
Removal, installation of engine front

seal
Removal, installation of engine rear

seal
01050-32050
Bolt
"
790-331-1110
Wrench
"
791-451-1000
Remover
"
790-101-2102
Puller (294 kN {30 ton})
"
790-101-1102
Pump
"
795-799-5410
Adapter
"
795-799-5420
Remover
"
790-413-1010
Bracket
"
790-501-5000
Repair stand (100 V)
"
790-415-1011
Bracket
"
750-501-5000
Repair stand (100 V)
"
Disassembly, assembly of torquflow

transmission assembly
Removal, installation of snap ring
791-615-1130
Push tool
"
791-615-1200
Ring assembly
"
791-615-1210
Ring
Tightening of cylinder head bolt

Removal, installation of radiator
guard assembly
Removal, installation of injector assembly

Disassembly, assembly of torque
converter assembly
135-A90-1150
Bolt
01580-01008
Nut
01641-51032
Washer
791-615-1101
Ring assembly
791-615-1111
Ring
Installation of No. 3 ring gear
2
"
1
1
135-A90-1150
Bolt
01580-01008
Nut
01641-51032
Washer
799-301-1600
Oil leak tester
"
Installation of No. 1 ring gear
Operation check of clutch piston
30-8-1
4
SPECIAL TOOL LIST
Component
Symbol
1
Pivot shaft assembly
Equalizer bar
Part No.
791T-650-2330
N !
N !
Plate
"
Bolt
"
790-101-2510
Block
"
790-101-2570
Washer
"
01580-01613
Nut
"
01643-31645
Washer
"
790-105-2300
Jack assembly
"
790-101-1102
Pump
"
791-650-1300
Remover
791-735-1123
Sleeve
790-434-1050
Screw
01580-02419
Nut
01643-32460
Washer
790-101-2102
3
U
4
791T-650-2340
30-8-8
"
790-201-3310
Hydraulic cylinder
assembly
Sleeve
Removal, installation of pivot shaft

assembly
Removal, installation of equalizer

bar
Pump
Bracket
"
N !
2 791T-650-2420
Bracket
"
N !
3 790-438-1110
Screw
"
4 791-112-1180
Nut
"
5 790-101-2540
Washer
"
6 790-101-2102
"
7 791-101-1102
Pump
"
790-502-1003
Cylinder
Repair stand
790-201-1702
Push tool KIT
"
790-201-1841
Push tool
790-201-1861
Push tool
790-101-5021
Clip
01010-50816
Bolt
790-201-1500
Push tool KIT
790-201-1650
Plate
790-201-1670
Plate
790-101-5021
Clip
01010-50816
Bolt
790-720-1000
Expander
"
796-720-1680
Ring
"
07281-01589
Clamp
"
796-720-1720
Ring
"
07281-02429
Clamp
"
796-720-1690
Ring
"
07281-02169
Clamp
"
790-102-2302
or
790-330-1100
Wrench
"
790-101-1102
Pump
"
790-101-1102
Nature work remarks
1 791T-650-2410
Equalizer bar bushing
Part name
Disassembly, assembly of equalizer

bar for bushing
Disassembly, assembly of hydraulic

cylinder assembly
"
Press fitting of bushing
Multi wrench
Press fitting of seal
Installation of piston ring
Tightening of cylinder head
D375A-5
SKETCHES OF SPECIAL TOOLS

Note: komatsu cannot accept any responsibility for special tools manufactured according to these sketches.
L1
Plate
L8
Plate
30-8-10
(7)
4
D375A-5
L10
Push tool
L13
Plate
D375A-5
30-8-11
(7)
4
L17 Guide
L21 Sling tool
30-8-12
(7)
4
D375A-5
L21 Tube
L21 Plate
D375A-5
30-8-13
(7)
4
P1 Sleeve
P2 Plate
30-8-14
(7)
4
D375A-5
N2-1 Bracket
N2-2 Bracket
D375A-5
30-8-15
(7)
4

FUEL PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL PUMP ASSEMBLY
REMOVAL
INSTALLATION
1. Close fuel supply valve.
2. Remove engine left side covers (1) and (2).
Carry out installation in the reverse order to removal.
Bleed air from fuel circuit.

1) Remove air bleed valve (1).
2) Fill with clean fuel through hole in valve until
it overflows.
Amount of fuel: Approx. 300 cc (reference)
3) Install air bleed valve (1).
3 Air bleed valve:
12.7 Nm {1.3 kgm}

4) Crank engine with starting motor.
3. Disconnect fuel tubes (3) and (4).

4. Remove fuel hose (5).
5. Disconnect wiring connector (6).
6. Remove clamps (7) and (8).
7. Loosen fuel pump mounting bolt (9) and remove
fuel pump assembly (10).
D375A-5
30-9
2 "
"

OF ENGINE FRONT SEAL
REMOVAL AND
INSTALLATION
SPECIAL TOOLS
Symbol
1
A
3
Part No.
Part name
INSTALLATION
Ne- Q'ty New/Re- Sketch
cessity
model
795-902-1410 Sleeve
01050-32240
795-902-1430 Push tool
01050-32235
Bolt
Bolt
q1
a Align the crankshaft pulley with the dowel pin

when installing.
a Tighten the mounting bolts in the order
shown in the diagram below.
3 Crankshaft pulley mounting bolt:
1st step:
73.5 19.6Nm {7.5 2kgm}
2nd step:
245 19.6Nm {25 2kgm}
3rd step:
637 19.6Nm {65 2kgm}
REMOVAL
1. Remove radiator guard assembly. For details,
see REMOVAL OF RADIATOR GUARD ASSEMBLY.
2. Remove crankshaft pulley (1).
q1
3. Remove front seal (2).
q2
q2
30-10
2 c
(7)
Procedure for assembling standard seal

a Fill the lip portion with approx. 5 cc of lithium
grease (G2-LI).
a Using tool A3, press fit front seal (2) to front
cover (3).
a After press fitting, check installation dimension a.
Front seal installation dimension a:
66 mm (standard)
D375A-5

Procedure of assembling front seal with sleeve

(for repair)
1) Using tool A1, guide bolt 1 , and nut 2 ,
press fit sleeve (4) to crankshaft (5).
Tighten 3 nuts 2 uniformly.
Press fit until tool A1 contacts the end
face of the crankshaft.
After press fitting, check that sleeve installation dimension b is the specified dimension.
Sleeve installation dimension b:
68 0.1mm
2) Using tool A3, press fit front seal (6) to front

cover (3).
a Fill the lip portion with approx. 5 cc lithium grease (G2-LI).
a After press fitting, check installation dimension c.
Front seal installation dimension c:
66 mm (standard)
D375A-5
30-11
2
(7) c

ENGINE REAR SEAL
REMOVAL AND
INSTALLATION OF
ENGINE REAR SEAL
SPECIAL TOOLS
Symbol
Part No.
Part name
795-902-1420 Sleeve
795-902-1440 Push tool
01050-32050
01582-02016
4

cessity
model
2 795-902-1450 Bolt
A
5. Remove rear seal (2).
Nut
Bolt
REMOVAL
1. Remove damper assembly. For details, see REMOVAL OF DAMPER ASSEMBLY.
2. Remove 1 mounting bolt of flywheel (1) and install guide bolt 1 .
3. Using eyebolts 2 , sling flywheel (1), then remove remaining mounting bolts.
q1
4. Move flywheel towards you, then lift off.
The spigot portion of the flywheel is shallow
and it may suddenly fall, so be careful not to
get your fingers caught.
q2
4
30-12
c
2 c
INSTALLATION
q1
Coat the thread and seat of the flywheel

mounting bolts with anti-friction compound
(LM-P).
Secure the flywheel and the housing with
stopper 3 , then tighten the mounting bolts.
Flywheel: 45kg
D375A-5

ENGINE REAR SEAL
a Tighten the flywheel mounting bolts in the order

3 Flywheel mounting bolt:
1st step: 98 19.6Nm {10 2kgm}
2nd step: 294 19.6Nm {30 2kgm}
3rd step: 539 19.6Nm {55 2kgm}
q2
Procedure for assembling standard seal.

a Using tool A4, press fit the rear seal (2) until
it contacts the flywheel housing.
Assembly procedure for seal with sleeve (for

maintenance)
1) Using tool A2, guide bolt 5 , and nut 6 ,
press fit sleeve (3) to crankshaft (4).
a Tighten 2 nuts 6 uniformly.
a Press fit until tool A2 contacts the crank.
a After press fitting, check that mounting
dimension a of sleeve is the specified dimension.
Sleeve mounting dimension a:27 1mm
a After installing the flywheel, use dial gauge 4 to

measure the radial and face runout of the flywheel.
Face runout: Max. 0.15 mm
Radial runout: Max. 0.20 mm
2) Using tool A4, press fit rear seal (5) until it

contacts flywheel housing (6).
D375A-5
30-13
2
(7) c

CYLINDER HEAD ASSEMBLY
REMOVAL AND
INSTALLATION OF
SPECIAL TOOLS
Symbol
A
A5
Part No.
5. Disconnect water tube (3).

Part name

model
cessity
795-799-5410
Adapter
"
795-799-5420
Remover
"
790-331-1110
Wrench
"
6. Remove wiring (4) and wiring clamp.
REMOVAL
Disconnect the cable from the negative () terminal of the battery.
1. Drain coolant.
2. Remove hood assembly. For details, see REMOVAL OF HOOD ASSEMBLY.
3. Remove engine right side cover (1).
7. Remove air cleaner dust discharge tube, hose,

and clamp (5).
8. Remove dust indicator hose (6).
9. Remove suction tube (7).
10. Remove left and right air cleaner assembly
mounting bolts (8).
11. Remove hose (9) and tube (10) between turbocharger and aftercooler.
12. Lift off air cleaner assembly (11).
4
Air cleaner assembly: 45 kg
4. Remove engine left side cover (2).
30-14
!
2 !
4
D375A-5

13. Remove alternator (12).
21. Remove adiabatic cover (24).
14. Remove U-bolt, and disconnect bracket (13) and

water tube (14).
15. Remove tube (15).
22. Lift off muffler assembly (25).
16. Remove fuel tube (16), fuel hose (17), and fuel
filter assembly (18).
17. Disconnect corrosion hose (19), and remove
corrosion resistor assembly (20).
18. Disconnect electrical intake air heater wiring
(21).
19. Disconnect fuel tube (22).
20. Lift off aftercooler assembly (23).
q1
q2
23. Disconnect turbocharger inlet lubrication tube

(26) and outlet tube (27), then disconnect exhaust temperature wiring.
D375A-5
30-15
2 !
4

24. Sling turbocharger assembly and exhaust manifold (28) as one unit, then loosen mounting bolts
q3
and remove.
4
Turbocharger,
exhaust manifold assembly:
27. Remove cylinder head cover (32).
30-16
2 !
4
q7
31. Remove mounting bolts, then remove rocker arm

housing (37).
q8
q4
28. Remove rocker arm assembly (33).

q5
Loosen the locknut, then loosen the adjustment screws 2 or 3 turns.
q6
30. Using tool A, remove injector assembly (36).
60kg
25. Remove air cleaner bracket and wiring clamp.

26. Remove spill hose (30).
29. Remove crosshead (34) and push rod (35).
32. Loosen cylinder head mounting bolts (38), then

using eyebolts, remove cylinder head assembly
(39).
q9
4
Cylinder head assembly: 60kg
D375A-5

INSTALLATION
q1
3 Delivery tube sleeve nut:

92.5 2.5Nm {9.45 0.25kgm}
q2
Tighten the aftercooler mounting bolts in the order shown in the diagram below.
3 Mounting bolt:
66.15 7.35Nm {6.75 0.75kgm}
q4

31.85 2.45Nm {3.25 0.25kgm}
q5
Clean the hole of the mounting bolts and install.

Check that the ball portion of the adjustment
screw is fitted securely in the socket portion of
the push rod.
3 Rocker arm mounting bolt:
98 4.9Nm {10 0.5kgm}
3 Locknut: 67.62 9.8Nm {6.9 1kgm}

q6
Adjust the crosshead as follows.

1) Loosen the locknut, then turn back the adjustment screw.
2) Hold down the top surface of the crosshead
lightly, and screw in the adjustment screw.
3) After the adjustment screw contacts the
valve stem, screw it in a further 20.
4) Tighten the locknut to hold the adjustment
screw in position.
3 Locknut: 58.8 5.88Nm {6 0.6kgm}
q3
Tighten the turbocharger and exhaust manifold

mounting bolts in the order shown in the diagram
below.
3 Turbocharger, exhaust manifold assembly mounting bolt:

110.35 12.25Nm {11.25 1.25kgm}
D375A-5
q7
3 Injector mounting bolt:

1st step : 29.4 4.9Nm {3 0.5kgm}
2nd step : Tighten 90 - 120
q8
3 Rocker arm housing mounting bolt:

98 4.9Nm {10 0.5kgm}
30-17
2 !
4

q9
Check that there is no dirt or dust on the cylinder

head mounting surface or inside the cylinder.
Check that the grommet does not come out
when installing the gasket.
Tighten the cylinder head mounting bolts in the
order shown in the diagram.
After tightening, make one punch mark a on the

main bolt head (if the bolt is new, do not make
any punch mark).
2 Mounting bolt:
Anti-friction compound (LM-P)
3 Cylinder head mounting bolts (1 - 7 ):

1st step:
245 9.8Nm {25 1kgm}
2nd step:
382.5 9.8Nm {39 1kgm}
3rd step:
Make marks with paint on bolt
and head, then tighten a further 90 - 120 .
(The mounting bolts may be
tightened to the above angle
with tool A5.)
3 Mounting bolts (8 - 9 )
98.1 4.9Nm {10 0.5kgm}
30-18
!
2 !
4
Refilling with water

Add water through water filler to the specified
level. Run the engine to circulate the water
through the system. Then check the water level
again.
D375A-5

FUEL TANK ASSEMBLY
REMOVAL AND
INSTALLATION OF
FUEL TANK ASSEMBLY
REMOVAL
5. Disconnect fuel return hose (7) and hose clamp

(8).
1. Remove covers (1) and (2).
6. Lift off fuel tank assembly (9).

4
Fuel tank assembly:

Approx. 500 kg (when empty)
Approx. 1350 kg (when full)
2. Disconnect wiring connector (CN-422) (3).

3. Close fuel supply valve and disconnect fuel supply hose (4).
4. Disconnect brackets (5) and (6).
INSTALLATION

3 Fuel tank mounting bolt:
927 98Nm {94.5 10kgm}
D375A-5
30-19
2 "
"

RADIATOR ASSEMBLY
REMOVAL AND
INSTALLATION OF
RADIATOR ASSEMBLY
REMOVAL
8. Disconnect sub tank hose (7).
9. Disconnect radiator water level sensor connector

(CN-405) (8).
1. Drain coolant.
10. Remove windbreaker plate (9).
2. Remove inspection cover (17).
11. Using eyebolts, sling radiator assembly, then remove 2 each of left and right top mount bolts
(10).
3. Disconnect front lamp connector (CN-202) (1).

4. Using eyebolts, lift off radiator top cover (2).
4
Radiator top cover: 76kg
12. Remove 2 covers (11).

13. Open guard (12).
5. Disconnect radiator inlet hose (3) and aeration
hose (4).
6. Remove ground wiring (CN-GND4) (5).
7. Disconnect wiring clamps (6) (4 places), and
move wiring towards left side of radiator.
30-20
"
2 "
D375A-5

RADIATOR ASSEMBLY
14. Remove windbreaker plate (13).
INSTALLATION

3 Radiator inlet hose clamp:
882 98Ncm {90 10kgcm}
3 Aeration hose clamp:

333.2 49Ncm {34 5kgcm}
Add water through water filler to the specified level.
Run the engine to circulate the water through the
system. Then check the water level again.
15. Disconnect radiator outlet tube (14).
16. Remove bottom mount bolt (15).
17. Lift off radiator assembly (16).

4
D375A-5
Radiator assembly: 390kg
30-21
2 "
"
REMOVAL AND INSTALLATION OF RADIATOR

GUARD ASSEMBLY
REMOVAL AND
INSTALLATION OF RADIATOR
GUARD ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.
Part name
791-451-1000 Remover
A
6 790-101-2102
Puller
(294kN {30ton})
790-101-1102 Pump

model
cessity
#
2. Disconnect hose (2).

Release the remaining pressure in the hydraulic circuit. For details, see TESTING
AND ADJUSTING, Releasing remaining
pressure in hydraulic circuit.
Fit a blind plug to prevent any dirt or dust
from entering.
REMOVAL
1. Remove cap (1) of blade lift cylinder.
Check the number and thickness of the
shims, and keep in a safe place.
Start the engine, and retract the piston rod,
then tie the piston rod with wire to prevent it
from coming out.
3. Sling blade lift cylinder assembly (3), then fit cylinder holder and secure to radiator guard.
4. Drain coolant.
30-22
"
2 "
D375A-5
6. Disconnect radiator inlet hose (4).

Disconnect at the radiator end and move it
towards the engine.
7. Disconnect aeration hose (5) and hose (6) from
reserve tank.
Disconnect at the radiator end, then remove
2 clamps and move towards the engine.

GUARD ASSEMBLY
10. Open engine underguard.

11. Remove right undercover of radiator guard, then
remove radiator outlet tube (11).
Loosen the clamp at the hose portion, then
remove the tube.
12. Disconnect wiring connector (12) (CN-21), and

remove cover (13).
8. Disconnect PPC oil cooler piping (7) and (8).
13. Disconnect blade piping (14) and (15).
9. Disconnect fuel cooler piping (9) and (10).
D375A-5
30-23
2 "
"

GUARD ASSEMBLY
14. Loosen tension of tension pulley (16) and remove fan belt (17).
17. Lift off radiator guard assembly (20).

Be careful not to damage the wiring and piping when removing.
4
15. Sling radiator and guard assembly, remove lock

bolt, then using tool A6, push rear pin (18) to inside radiator guard, and remove.
16. Remove lock plate, and using tool A6, pull front
pin (19) to outside of radiator guard, and remove.
Radiator guard assembly: 2,700kg
INSTALLATION

Standard shim thickness: 4mm

882 98Ncm {90 10kgcm}

333.2 49Ncm {34 5kgcm}
3Radiator outlet hose clamp:

882 98Ncm {90 10kgcm}

30-24
"
2 "
D375A-5

ENGINE ASSEMBLY
REMOVAL AND
INSTALLATION OF
ENGINE ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.
Part name

model
cessity
799-703-1200 Service tool kit
5. Remove air cleaner dust discharge tube hose

clamp (3).
6. Remove air cleaner band (4).
7. Remove air supply tube clamp (5), then remove
air supply tube (6).
799-703-1100 Vacuum pump
8. Disconnect dust indicator hose (7).
9. Lift off air cleaner assembly (8).
799-703-1401
Gas leak
detecter
4 Air cleaner assembly: 22kg
REMOVAL
Disconnect the cable from the negative () terminal of the battery.1.
1. Drain coolant.
2. Remove engine hood assembly.
3. Remove engine right side cover (1).
10. Disconnect ground connection wiring (9).

11. Disconnect starting motor wiring (10).
12. Close heater valve (11), and move engine to
rear.
4. Remove engine left side cover (2).
D375A-5
30-25
2
(7) c
13. Remove torque converter oil cooler connector

(12).
14. Disconnect radiator outlet tube (13).
15. Disconnect air conditioner hoses (16) and (17).

a Collect air conditioner gas (R134a) completely
before disconnecting the hoses.
a Fit blind plugs to prevent dirt, dust, or moisture from getting inside the hoses.
a Disconnect all clamps of hoses (16) and
(17).

ENGINE ASSEMBLY
16. Disconnect fuel supply hose (18).

17. Disconnect fuel return hose (19) and remove
hose clamp.
18. Disconnect wiring connectors (CN-101) (20),

(CU-EG1) (21), and (CU-EG2) (22).
19. Disconnect radiator inlet hose (23).

Disconnect aeration hose (24).
30-26
2 c
(7)
D375A-5

ENGINE ASSEMBLY
20. Remove fan net (22).

21. Loosen tension of tension pulley (23) and remove fan belt (24).
26. Lift off bracket assembly (32).

4
Bracket assembly: 170kg
27. Remove damper case oil level gauge (33).

22. Remove right covers (25) and (26).
28. Remove bracket (34).
23. Remove left covers (27) and (28).

29. Sling universal joint (35), remove mounting bolts,

then lift off.
25. Disconnect wiring connectors (CN206) (30) and
(CN-201) (31).
D375A-5
30-27
2 "
"

ENGINE ASSEMBLY
30. Remove front mount bolt (36) and rear mount

bolt (37).
31. Raise engine assembly (38), and remove right
rear mount cap (39).
4
Engine assembly: 3,200kg
32. Move engine assembly (38) to above chassis

and operate chain block to raise front of engine
assembly and set assembly at an angle.
33. Pass chassis parts through front and rear of engine assembly (38), then rotate engine assembly
(38) 90 to right of chassis and remove.
When removing, be careful not to damage
the wiring and hoses.
INSTALLATION
Be careful to prevent the entry of moisture, dust
or dirt into the air conditioner circuit hoses when
installing.
Check that there are O-rings at the portion of the
air conditioner hoses connecting to the piping,
then tighten. Coat the O-rings thoroughly with
compressor oil (Showa-Shell Suniso 4G or 5G).
3 Air conditioner gas piping tightening

torque
Thread size
Tightening torque
16 1.5
13.23 1.47Nm {1.35 0.15kgm}
22 1.5
22.05 2.45Nm {2.25 0.25kgm}
24 1.5
31.85 2.45Nm {3.25 0.25kgm}
M6 bolt
(receiver portion)
5.39 1.47Nm {0.55 0.15kgm}
M6 bolt
9.8 1.96Nm {1.0 0.2kgm}
(compressor portion)

882 98Ncm {90 10kgcm}

333.2 49Ncm {34 5kgcm}
3 Universal joint mounting bolt:

176.4 19.6Nm {18 2kgm}
3 Engine mount bolt:

926.1 102.9Nm {94.5 1kgm}
Charging air conditioner with gas
Using tool X, charge the air conditioner circuit with
air conditioner gas (R134a).
30-28
"
2 "
D375A-5

DAMPER ASSEMBLY
REMOVAL AND
INSTALLATION OF
DAMPER ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.
Part name
5. Remove right covers (5) and (6).

cessity
model
799-7.3-1200 Service tool kit
Gas leak de799-703-1401

tector
6. Remove left covers (7) and (8).

REMOVAL
2. Disconnect ground connection wiring (1).
8. Disconnect wiring connector (CN-206) (10).
3. Disconnect starting motor wiring (2).

4. Close heater valve, then remove heater hose
clamp, and disconnect heater hoses (3) and (4).
q1
D375A-5
30-29
2
(7) c

DAMPER ASSEMBLY
9. Disconnect air conditioner hoses (11) and (12).

a Collect air conditioner gas (R134a) completely
before disconnecting the hoses.
a Fit blind plugs to prevent dirt, dust, or moisture from getting inside the hoses.
13. Open power train underguard (front).

14. Sling universal joint (27), then remove mounting
bolts, and lift off.D
q2
4 Universal joint: 45kg
10. Lift off bracket (13).
4 Bracket assembly: 170kg
15. Remove drain plug and drain oil from damper

case.
11. Remove damper case oil level gauge (25).
Damper case: Approx. 2.1
16. Remove holder (28) and coupling (29).
q3
17. Remove retainer (30).
30-30
2 c
(7)
D375A-5

DAMPER ASSEMBLY
18. Using eyebolts 1 , sling damper cover (31), then

q4
use forcing screws to remove.
To prevent the damper cover from coming
out suddenly, set guide bolt 2 (=200mm).
4
Damper cover: 75kg
19. Using eyebolts 3 , remove damper assembly

(32).
q5
To prevent the damper assembly from comi n g o u t s u d d e n l y, s e t g u i d e b o l t 4
(=200mm).
4
Damper assembly: 70kg
20. Remove bearing (33) from flywheel.
q6
INSTALLATION
q1
Install the hoses without twisting or interference.

Be careful to prevent the entry of moisture,
dust or dirt into the air conditioner circuit hoses when installing.
Check that there are O-rings at the portion of
the air conditioner hoses connecting to the
piping, then tighten.
Coat the O-rings thoroughly with compressor oil (Showa-Shell Suniso 4G or 5G).
3 Air conditioner gas piping tightening

torque
Thread size
Tightening torque
16 1.5
13.23 1.47Nm {1.35 0.15kgm}
22 1.5
22.05 2.45Nm {2.25 0.25kgm}
24 1.5
31.85 2.45Nm {3.25 0.25kgm}
q2

176.4 19.6Nm {18 2kgm}
q3
2 Holder mounting bolt thread portion:

Thread tightener (LT-2)
276.85 31.85Nm {28.25 3.25kgm}
D375A-5
30-31
2 "
"

DAMPER ASSEMBLY
q4
Using guide bolt 2 (=200 mm), dtermine

the position of the damper cover.
q5
Using guide bolt 4 (=200 mm), dtermine

the position of the damper assembly.
q6
Fill approx.50% (approx. 11 g) of the hatched

portion a in the diagram with grease (G2-LI).
Refilling with oil

Fill with oil to the specified level.
Charging air conditioner with gas

Using tool X, charge the air conditioner circuit with air conditioner gas (R134a).
30-32
"
2 "
D375A-5
DISASSEMBLY AND ASSEMBLY OF DAMPER
DISASSEMBLY AND
ASSEMBLY OF DAMPER
DISASSEMBLY OF DAMPER ASSEMBLY
6. Remove seal (7) from flanges (2) and (5).
1. Set damper assembly to block 1 .

2. Remove mounting nut (1), then using forcing
screws 2 , remove flange (2).
DISASSEMBLY OF DAMPER COVER

ASSEMBLY
3. Remove shaft (3).
7. Remove bearing (8) and oil seal (9) from cover

(10).
4. Remove rubber (4).
8. Remove oil seal (11) from retainer (12).
5. Using forcing screws 2 , remove flange (5) from

body (6).
D375A-5
30-33
2 "
"
ASSEMBLY OF DAMPER ASSEMBLY

1. Install seals (7) to flanges (2) and (5).
Install the seal with the lip facing the inside
as shown in the diagram.
3. Set flange and body assembly to block, then set

shaft (3) in position.
4. Assemble rubber (4).
When assembling the rubber, coat the whole
surface of the rubber, the outside circumference of the shaft, and the inside circumference of the body with grease (G2-LI).
After assembling to the rubber, fill approx.
30% of the clearance (16 places) between
the flange and body with grease (G2-LI).
2. Align bolt holes with body (6) and install flange

(5).
2 Mating surface of flange:
Check that there are no dents, rust, oil or

grease, or water on the mating surface, then
coat both faces of the flange and body with
gasket sealant.
5. Install flange (2).
2 Mating surface of flange:

Check that there are no dents, rust, oil or
grease, or water on the mating surface, then
coat both faces of the flange and body with
gasket sealant.
6. Set bolt in position, and tighten mounting nut (1).
30-34
"
2 "
D375A-5
ASSEMBLY OF DAMPER COVER ASSEMBLY

7. Using push tool 3 , press fit oil seal (11) to retainer (12).
2 Oil seal press-fitting surface:
Coat the inside surface of the retainer thinly

with gasket sealant and wipe off any sealant
that is squeezed out.
9. Using push tool 5 , press fit oil seal (9) to cover

(10).
2 Oil seal press-fitting surface:
Coat the inside surface of the retainer thinly

with gasket sealant and wipe off any sealant
that is squeezed out.
2 Lip of oil seal: Grease (G2-LI)
8. Using push tool 4 , press fit bearing (8) to cover

(10).
D375A-5
30-35
2 "
"
REMOVAL AND INSTALLATION OF POWER

TRAIN UNIT ASSEMBLY
REMOVAL AND
INSTALLATION OF POWER
TRAIN UNIT ASSEMBLY
REMOVAL
1. Drain oil from hydraulic tank and power train
case.
6
Hydraulic tank: Approx. 120
Power train case: 150
9. Disconnect wiring connectors (CN-PL1) (7),

(CN-PL2) (8), and (CN-PL3)(9).
10. Loosen locknut and remove from bracket.
2. Remove floor frame assembly. For details, see

REMOVAL OF FLOOR FRAME ASSEMBLY.
3. Remove fuel tank. For details, see REMOVAL
OF FUEL TANK ASSEMBLY.
4. Remove 2 clamps (1) of hydraulic and PPC
pump inlet tube coupling.
Move the coupling towards the power train
unit and disconnect the tube.
5. Disconnect PPC drain hose (2).
Disconnect at the pump inlet tube end, and
move it to the right side of the chassis.
11. Disconnect torque converter oil cooler hose (10).
6. Disconnect 2 PPC oil cooler hoses (3), then disconnect clamps (2 places).
Move the 2 hoses together to the outside of
the oil level gauge, then move them to the
right side of the chassis.
7. Disconnect hydraulic and PPC pump outlet hose
(4).
Disconnect at the pump end.
8. Disconnect wiring connectors (CN-241) (5) and
(CN-404) (6), then disconnect clamps (2 places).
12. Disconnect right rear lamp connector (CN-243)
(11), then disconnect clamps at top of frame (3
places) and at bottom of frame (1 place).
13. Remove frame (12).
30-36
"
2 "
D375A-5
14. Disconnect torque converter oil cooler hose (13),

then disconnect bracket at frame end.
Move the hose towards the front of the chassis.

TRAIN UNIT ASSEMBLY
18. Disconnect universal joint (18) at torque converter end.

After disconnecting, move it towards the
damper end.
15. Disconnect ripper low valve hose (14), then disconnect bracket (1 place) on top of steering
case.
Move the hose towards the power train unit
end.
16. Disconnect 2 pin puller solenoid hoses (15), then
disconnect clamp.
Disconnect the hose at the steering case
end, and move it towards the ripper end.
19. Remove cover (19), then using eyebolts, pull out

left and right drive shaft (30).
If the shaft does not come out, push up the
shoe grouser from the ground surface with a
jack and move the sprocket backwards or
forwards to adjust to a position where the
shaft can be removed, then pull the shaft out.
Pull the shaft out to a point where it contacts
the sprocket.
17. Disconnect clamps (16) and (17) and remove
bracket.
Move the hose towards the right side of the
chassis.
D375A-5
30-37
2 "
"
20. Remove right floor frame rear mount (21).

Remove at this point because the right floor
frame rear mount will interfere when the
power train unit is raised.
21. Remove left floor frame mount (22) and right

floor frame mount (23).
The front mount of the power train unit is
tightened together with the front mount of the
floor frame.
4
30-38
"
2 "

TRAIN UNIT ASSEMBLY
22. Remove left and right rear mount caps (24).
23. Loosen left and right rear coupling clamps (25).

Move the clamps towards the main frame,
open the joint of the coupling, then move the
seal towards the main frame.
Left floor frame mount: 38kg

Right floor frame mount: 37kg
D375A-5

TRAIN UNIT ASSEMBLY
24. Lift off power train unit assembly (26).

Check that all the wiring and piping has been
disconnected before removing the power
train unit assembly.
4
Power train unit assembly: 4,200kg
Refilling with oil (power train case, hydraulic

tank)
Add oil through oil filler to the specified level.
Run the engine to circulate the oil through
the system. Then check the oil level again.
5
Power train case: Approx.150
Hydraulic tank: Approx.120
INSTALLATION

176.4 19.6Nm {18 2kgm}
If the shaft does not go in, push up the shoe
grouser from the ground surface with a jack
and move the sprocket backwards or forwards to adjust to a position where the shaft
meshes, then assemble the shaft.
3 Rear mount cap mounting bolt:
367.5 61.25Nm {43.75 6.25kgm}
3 Rear coupling clamp mounting bolt:
6.85 1.96Nm {0.7 0.2kgm}
When installing the power train unit assembly, pay attention to the mating surface of the
coupling and be careful not to damage the
coupling seal at the rear mount.
D375A-5
30-39
2 "
"
DISCONNECTION OF POWER
TRAIN UNIT ASSEMBLY
TRAIN UNIT ASSEMBLY
1. Draining oil
Before setting power train unit assembly in position, drain oil from oil pan.
2. Raise power train unit assembly (1) and set to
block 1 .
Set blocks under the front of the oil pan, under the transmission rear case, and under
the steering case.
6. Disconnect 14 pressure detection hoses (5) and

remove central pressure detection bracket (6) as
one unit.
Before removing, mark all the hoses with
tags to prevent mistakes in the mounting position when installing.
7. Remove oil level gauge (7).

8. Remove oil filler pipe (8).
3. Remove brake rod (2).
4. Remove parking brake cable (3).
Measure the dimension of the mounting
bracket portion.
5. Remove control cable and bracket assembly (4).
Disconnect the directional control cable and
speed control cable together with the lever at
the control valve end.
30-40
"
2 "
D375A-5
TRAIN UNIT ASSEMBLY
9. Lift off filter assembly (9) together with bracket.

4
Filter assembly: 120kg
12. Lift off scavenging pump assembly (12).

4
Scavenging pump assembly: 41kg
10. Lift off strainer assembly (10) together with suction tube.
4
Strainer assembly:50kg
13. Lift off front mount (13).

4
Front mount: 150kg
11. Lift off power train and lubrication pump assembly (11).
4
Power train, lubrication pump assembly:

50kg
14. Remove outlet hose of hydraulic and PPC pump.

15. Lift off hydraulic and PPC pump assembly (14)
together with inlet tube.
4
D375A-5
Work equipment, PPC pump assembly:

65kg
30-41
2 "
"
TRAIN UNIT ASSEMBLY
16. Disconnect hydraulic hoses (35) and (36) of servo valve (34).
20. Remove block from under oil pan, and sling oil
pan (17).
17. Disconnect bolts (37) and (38).
21. Remove mounting bolts, then remove oil pan

(17).
In addition to the mounting bolts at the front,
rear, left, and right, there are also bolts installed inside the holes at 4 places under the
oil pan.
18. Remove 3 bolts (39), then remove servo valve

(34).
Oil pan: 110kg
19. Disconnect steering control rod (15) at control

valve end, and remove together with lever assembly (16).
22. Remove bearing cage (18) together with torque
converter speed sensor.
23. Remove case (19).
30-42
"
2 "
D375A-5
24. Remove shaft (20).
TRAIN UNIT ASSEMBLY
28. Set PTO, torque converter, and transmission assembly (22) with PTO side at top, then set on
block 3 .
25. Set block 2 under PTO.

26. Sling steering case assembly (21), and remove
block from under steering case.
29. Remove coupling (23).

30. Remove retainer (24).
27. Remove mounting bolts, then remove steering

case assembly (21).
4
D375A-5
Steering case assembly: 1,750kg
31. Remove snap ring (25), then remove spacer

(26).
30-43
2 "
"
TRAIN UNIT ASSEMBLY
32. Using eyebolts, lift off PTO assembly (27).

4
PTO assembly: 290kg
33. Lift off torque converter assembly (28).

4
30-44
"
2 "
Torque converter assembly: 550kg
D375A-5
CONNECTION OF POWER TRAIN UNIT ASSEMBLY
CONNECTION OF POWER
TRAIN UNIT ASSEMBLY
Carry out connection in the reverse order to disconnection.
Bend the cotter pin securely.

Set the installation dimension of the bracket to
the dimension measured when removing.
Adjust the limit switch and the lever of the directional control linkage as follows.
1) Set lever (29) to N position and insert.
2) Set up and down lever (29) at a height where
roller of up and down limit switch (30) contacts groove in lever (29), then tighten temporarily.
3) Move lever (29) to F and R positions and
check that roller is pushed in securely [F: top
limit switch], [R: bottom limit switch], then
tighten lever (29) fully.
Bend the cotter pin securely.
D375A-5
Check that the tip of shaft (20) is fitted securely

in drum (31) of bearing cage (18).
Check that shaft (20) is fitted securely in boss

(32) at the tip of the transmission input shaft.
30-45
2 "
"
3 Steering case mounting bolt:

276.85 31.85Nm {28.25 3.25kgm}
Adjust the retainer shim as follows.
1) Without fitting shim, install retainer (24) and
tighten 6 mounting bolts to following torque.
2 Oil seal: Grease (G2-LI)
3 Mounting bolt: 9.8Nm {1kgm}

2) Using clearance gauge, measure clearance
a between retainer (24) and PTO housing
(33).
CONNECTION OF POWER TRAIN UNIT ASSEMBLY
3) Select shim thickness.

Shim thickness = a + 0 - 0.05 mm
Types of shim thickness = 0.15 mm, 0.2 mm,
0.5 mm
4) Assemble selected shim thickness and tighten mounting bolts of retainer (24) to specified torque.
3 Mounting bolt:
66.15 7.35Nm {6.75 0.75kgm}
Check that the number and thickness of

the shims is the same on both the left
and right sides.
Assemble the shims (34) as shown in the
diagram below so that they do not block
the forcing screw tap H hole in the retainer.
Measure clearance a at 4 places (A, B, C, D)

around the circumference and calculate the average.
Coat portion P of the PTO shaft with anti-friction
compound (LM-P) and the spline portion Q with
grease (G2-LI).
30-46
"
2 "
D375A-5

PTO ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
PTO ASSEMBLY
DISASSEMBLY
1. PTO lubrication tube
Sling PTO assembly and remove lubrication tube
(1).
Remove 3 lubrication tubes on the opposite
side, then set the torque converter side at the
bottom and lower the assembly.
3) Using puller 2 , remove bearings (5) and (6)

from gear (7).
3. Power train pump gear assembly

1) Using forcing screws 1 , pull out cover assembly (8) and remove.
2) Using puller, remove gear assembly (10)
from cover (9).
2. Hydraulic, PPC pump gear assembly
1) Using forcing screws 1 , pull out cover assembly (2) and lift off.
2) Using puller 2 , remove gear assembly (3)
from cover (4).
D375A-5
30-47
2 "
"
3) Using puller 2 , remove bearings (11) and

(12) from gear (13).
4) Turn over PTO case, and remove cover (14).

1) Remove snap ring (15) at bottom of PTO
case, then remove gear (16).
30-48
"
2 "

PTO ASSEMBLY
5. Idler gear assembly

1) Remove plate (17).
2) Turn over PTO case, then using forcing

screws 1 , remove shaft assembly (18).
The bearing outer race and gear assembly will come out from the bottom of the
PTO case, so set a wooden block and
take care not to cause damage.
3) Remove plug (19), then using forcing
screws, push out bearing inner race (20).
After removing the bearing, install the
plug.
D375A-5
4) Remove bearing outer races (21) and (22)

from gear (23).
6. PTO race
1) Remove race assembly (24) and bearing
outer race (25) as one unit.

PTO ASSEMBLY
3) Remove bearing outer race (29).

4) Remove sleeve (30).
7. Bearing
Remove snap ring (31), then remove bearing
(32).
2) Remove bearing inner races (26) and (27)

from race (28).
D375A-5
30-49
2 "
"
ASSEMBLY
Wash all parts clean and check that there are no
scratches or dirt before assembling.
Check that the snap ring is fitted securely in the
groove.

PTO ASSEMBLY
3) Using push tool, press fit bearing inner races

(27) and (26) to race (28).
1. Bearing
1) Using push tool, press fit bearing (32) to
case.
Drop approx. 6 cc of engine oil
(SAE10W-CD or SAE30-CD) on the
bearing, and rotate it 10 times.
2) Install snap ring (31).
4) Install race assembly (24).
2 Inside surface of race:

5) Using push tool, press fit bearing outer race

(25).
2. PTO case
1) Install sleeve (30) to case.
Install the sleeve with the chamfered portion on the inside circumference facing
down.
Expand fit the sleeve.
(29).
30-50
"
2 "
D375A-5
3. Idler gear
1) Using push tool 3 , press fit bearing outer
races (22) and (21) to gear (23).

PTO ASSEMBLY
4) Turn over PTO case and install gear assembly (33).

5) Press fit bearing spacer (34) and bearing inner race (35).
2) Using push tool 4 , press fit bearing inner

race (20) to shaft.
3) Fit O-ring and install shaft assembly (18).
6) Install plate (17).
2 Mounting bolt:
3 Mounting bolt:
110.35 12.25Nm {11.25 1.25kgm}

1) Install gear (16).
2 Spline portion: Grease (G2-LI)
D375A-5
30-51
2 "
"
2) nstall snap ring (15) from bottom of PTO

case.
5. Power train pump gear assembly
1) Fit O-ring and install cover (14).

PTO ASSEMBLY
3) Using push tool 6 , press fit gear assembly

(10) to cover (9).
2 Gear spline portion:
Grease (G2-LI)
4) Fit O-ring, then raise cover assembly (8) and

install to case.
If the cover assembly is stiff and it is difficult to insert into the case, tap uniformly
around the circumference with a plastic
hammer to install.
2) Using push tool 5 , install bearings (11) and

(12) to gear (13).
6. Hydraulic, PPC pump gear assembly

1) Using push tool 5 , press fit bearings (5) and
(6) to gear (7).
30-52
"
2 "
D375A-5

PTO ASSEMBLY
2) Using push tool 6 , press fit gear assembly

(3) to cover (4).
At one end, the end face of the bearing is
level with the end face of the gear. Install
so that this end is facing the cover.
2 Gear spline portion:
7. Lubrication tube
Sling PTO assembly, and install lubrication tube
(1).
Install the 3 lubrication tubes on the opposite
side also.
Grease (G2-LI)
3) Fit O-ring, then raise cover assembly (2) and
install to case.
If the cover assembly is stiff and it is difficult to insert into the case, tap uniformly
around the circumference with a plastic
hammer to install.
D375A-5
30-53
2 "
"
DISASSEMBLY AND ASSEMBLY OF TORQUE

CONVERTER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF TORQUE
CONVERTER ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.
Part name

model
cessity
790-413-1010
Bracket
790-501-5000
Repair
stand
(100V)
DISASSEMBLY
Preparatory work
Set torque converter assembly (56) to tool C.
1. Torque converter valve assembly

Remove torque converter valve assembly (1).
2. Draining oil
Remove 2 drain plugs (2) and drain oil from
pump case.
After draining the oil, tighten the plugs.
3. Lock-up clutch, drive case assembly
1) Leaving 2 mounting bolts (3), remove other
mounting bolts, then set with input shaft at
top and remove remaining 2 mounting bolts.
2) Using eyebolts 1 , remove lock-up clutch

and drive case assembly (4).
3) Disassemble lock-up clutch and drive case
assembly as follows.
i) Remove 2 seal rings (5).
ii) Using forcing screws 2 , remove input
shaft (6).
30-54
"
2 "
D375A-5
iii) Remove snap ring (7), then remove plate

(8).
iv) Set with clutch housing at bottom, then
using forcing screws 3 , remove turbine
(9).

CONVERTER ASSEMBLY
vii) Remove seal ring (13) from piston.

viii) Remove seal ring (14) from housing.
ix) Using push tool 5 , remove bearing (15)

from housing.
v)
Set with clutch housing at top, then using

eyebolts 4 , remove housing and piston
assembly (10).
When the assembly is removed, the
piston will come out, so support it by
hand when removing.
vi) Remove piston (11) from housing (12).
x)
D375A-5
Remove 2 discs (16) and 1 plate (17)

from drive case (18).
Store the discs and plates in a flat
place to prevent them from becoming deformed.
30-55
2 "
"
4. Stator assembly
1) Remove snap ring (19), then remove stator
assembly (20).
2) Disassemble stator assembly as follows.
i) Remove snap ring (21), then remove
race (22) from stator (23).
ii)

CONVERTER ASSEMBLY
5. Pump assembly
1) Remove snap ring (25).
2) Remove pump assembly (26).
3) Disassemble pump assembly as follows.
i) Remove retainer (27).
ii) Remove bearing and guide assembly
(28) from pump (29).
Remove snap ring (24) from stator (23).

iii) Remove bearing outer race (30) from
guide (31).
6. Stator clutch housing
Set with stator clutch housing side at top, then
remove stator clutch housing (32).
30-56
"
2 "
D375A-5
7. Spring
Remove spring (33).

CONVERTER ASSEMBLY
2) Remove seal ring (42) from piston.

3) Remove seal ring (43) from case.
8. Spring, discs, plate

Remove spring (34), 2 discs (35), and 1 plate
(36).
Store the discs and plates in a flat place to
prevent them from becoming deformed.
9. Pin
Remove pin (37).
12. Stator shaft assembly

1) Tap stator shaft assembly (44) with plastic
hammer to remove from case (45).
2) Disassemble stator shaft assembly as follows.
i) Using push tool 6 , remove shaft assembly (45) from stator shaft assembly.
10. Inner gear

Remove snap ring (38), then remove inner gear
(39).
11. Piston
1) Remove piston (40) from case (41).
D375A-5
30-57
2 "
"

CONVERTER ASSEMBLY
ii)
Remove snap ring (47), then remove

bearing inner race (48), bushing (49),
and seal shaft (50) from shaft.
iii) Remove seal ring (51), then remove
plate (54).
iv) Remove snap ring (35), then remove
plate (54).
v)
ASSEMBLY
groove.
Preparatory work
Set case (41) to tool C.
Using push tool 7 , remove bearing (55).

1. Stator shaft assembly
1) Assemble stator shaft assembly as follows.
i) Using push tool, press fit bearing (55) to
stator shaft (52).
ii) Install plate (54) and secure with snap
ring (53).
iii) Install seal ring (51).
After installing the seal ring, coat
with grease (G2-LI) and fit securely
to shaft.
30-58
"
2 "
D375A-5
iv) Install seal ring (50) to shaft.

After installing the seal ring, coat
with grease (G2-LI) and fit securely
to the shaft.
v) Using push tool 9 , press fit bushing
(49).
Be careful not to deform the bushing
when press fitting.
vi) Using push tool 0, press fit bearing inner race (48).
vii) Install snap ring (47) and secure bearing
inner race.

CONVERTER ASSEMBLY
2) Tap stator shaft (52) with plastic hammer to

press fit bearing portion to case.
3) Set shaft (46) to stator shaft, then using push
tool, press fit bearing portion.
4) Turn over case, and tighten mounting bolts of
shaft from case end.
2 Outer circumference of seal ring:
Grease (G2-LI)
3 Mounting bolt:
66.15 7.35Nm {6.75 0.75kgm}
2. Piston
1) Install seal ring (43) to case.

Grease (G2-LI)
The seal ring must be installed facing in

the correct direction. Assemble as
shown in the diagram.
2) Install seal ring (42) to piston.
Grease (G2-LI)
D375A-5
30-59
2 "
"
The seal ring must be installed facing in

the correct direction. Assemble as
shown in the diagram.

CONVERTER ASSEMBLY
7. Stator clutch housing

Install stator clutch housing (32).
Check that the spring is fitted securely in the
piston and housing holes.
2 Mounting bolt:
3 Mounting bolt:
110.35 12.25Nm {11.25 1.25kgm}
3) Install piston (40) to case (41).
2 Mating surface of seal ring:

Grease (G2-LI)
8. Pump assembly
1) Assemble pump assembly as follows.
i) Using push tool, press fit bearing outer
race (30) to guide (31).
Drop approx.6 cc of engine oil (SAE10WCD or SAE30-CD) on the bearing, and
rotate it 10 times.
3. Inner gear
Install inner gear (39), and secure with snap ring
(38).
4. Pin
Install pin (37).
5. Plate, discs, spring
Install 1 plate (36), 2 discs (35), and spring (34).
6. Spring
Install spring (33).
30-60
"
2 "
D375A-5
ii)
Set bearing and guide assembly (28) to

pump (29), then tap with plastic hammer
to press fit bearing portion.
iii) Install retainer (27).

CONVERTER ASSEMBLY
9. Stator assembly
1) Assemble stator assembly as follows.
i) Install snap ring (24) to stator (23).
2 Mounting bolt:
3 Mounting bolt: 66.15 7.35Nm

{6.75 0.75kgm}
2) Install pump assembly (26).
When installing the pump, be careful not
to damage the seal ring assembled to
the shaft.
ii)
Assemble race (22) in stator (23), then

secure with snap ring (21).
2) Install stator assembly (20) to stator shaft,
then secure with snap ring (19).
D375A-5
30-61
2 "
"
10. Lock-up clutch, drive case assembly

1) Assemble lock-up clutch and drive case assembly as follows.
i) Set turbine (9) to block A , then set drive
case (18) to turbine.
ii)

CONVERTER ASSEMBLY
iii) Install seal ring (14) to housing.
2 Outer circumference of seal

Grease (G2-LI)
ring:
iv) Install seal ring (13) to piston.
2 Outer circumference of seal

Grease (G2-LI)
ring:
Install 2 discs (16) and 1 plate (17).

v)
Install piston (11) to housing (12).
2 Mating surface of seal ring:

Grease (G2-LI)
When installing, be careful not to

damage the seal ring.
vi) Using eyebolts 4 , install housing and
piston assembly (10).
2 Mounting bolt:
3 Mounting bolt:
110.35 12.25Nm
{11.25 1.25kgm}
30-62
"
2 "
D375A-5
vii) Using push tool, press fit bearing (15).

viii) Install plate (8) and secure with snap ring
(7).
ix) Install input shaft (6).
2 Mounting bolt:
3 Mounting bolt:
x)
277.0 31.9Nm
{28.5 3.25kgm}
Install 2 seal rings (5).

CONVERTER ASSEMBLY
3) Tighten mounting bolts (3).

Check that drain plug (2) has been tightened.
3 Mounting bolt:
53.9 4.9Nm {5.5 0.5kgm}
3 Drain plug:
11.25 1.45Nm {1.15 0.15kgm}
11. Torque converter valve assembly
Install torque converter valve assembly (1).
Tighten the mounting bolts equally to prevent
unbalanced tightening.
3 Mounting bolt:
49.0 4.9Nm {5.0 0.5kgm}
2) Using eyebolts 1 , install lock-up clutch and

drive case assembly (4).
Align the tturbine oil groove (marked a)
and drain plug (2) when installing.
D375A-5
30-63
2 "
"
DISASSEMBLY AND ASSEMBLY OF TORQFLOW

TRANSMISSION ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF TORQFLOW
SPECIAL TOOLS
Symbol
Part No.
Bracket
750-501-5000
Repair
stand
(100V)
Push tool
Ring assembly
791-615-1200
NeNew/ReQ'ty
Sketch
cessity
model
790-415-1011
2 791-615-1130
Part name
791-615-1210
Ring
135-A90-1150
Bolt
01580-01008
Nut
01641-51032
Washer
791-615-1101
Ring assembly
791-615-1111
Ring
135-A90-1150
Bolt
01580-01008
Nut
01641-51032
Washer
5 799-301-1600
Oil leak
tester

1) Remove tube.
2) Remove cover (2), then remove sleeve inside.
4) Remove control valve assembly (4) as one

unit with seat.
Remove the 4 mounting bolts marked *.
Do not remove any other bolts.
DISASSEMBLY
1. Preparatory work
Set transmission assembly (1) to tool D1.
3. Lubrication valve assembly

Remove lubrication valve assembly (5).
30-64
"
2 "
D375A-5
4. Front case
1) Set input shaft end at top and stand transmission assembly.
2) Using eyebolts, remove front case (6).
5. Input shaft, No. 1 carrier assembly

1) Remove 17 tie bolts (7).
2) Using forcing screws 1 , disconnect input
shaft and No. 1 carrier assembly (8).
Tighten the forcing screws uniformly, and
be careful not to twist the input shaft and
No. 1 carrier assembly.
D375A-5

3) Using eyebolts 2 , lift off input shaft and No.

1 carrier assembly (8).
4) Turn over input shaft and No. 1 carrier assembly, and remove seal ring (9).
5) Disassemble input shaft and No. 1 carrier assembly as follows.

i) Remove snap ring (10), then remove No.
2 sun gear (11).
ii) Remove spacer and bearing assembly
(12).
30-65
2 "
"
iii) Using push tool, remove ball bearings

(13) and (14) from spacer (15).

vi) Using eyebolts 3 , sling housing and No.

1 carrier assembly (18) and set on block.
Put the tip of the input shaft in contact with the ground and separate the
housing and No. 1 carrier assembly
from the block by approx. 20 mm.
vii) Remove snap ring (19).
iv) Remove No. 1 sun gear (16).

v) Remove spacer (17).
viii) Tap housing with plastic hammer and

drop housing and No. 1 carrier assembly
(20) on block to remove input shaft assembly (21).
ix) Using press, remove ball bearing (22)
from input shaft (23).
30-66
"
2 "
D375A-5
x)
Remove snap ring (24) from housing and

No. 1 carrier assembly (20).
xi) Set housing and No. 1 carrier assembly
on block, then using push tool 4 , remove housing (25) from No. 1 carrier assembly (26).
xii) Remove snap ring (27) from housing

(25).
xiii) Turn over housing and set on block, then
remove seal ring (146).
D375A-5

xiv) Using push tool 5 , remove ball bearing

(28) from housing.
xv) Remove spacer (29) from No. 1 carrier
assembly (26).
xvi) Turn over No. 1 carrier assembly, remove

snap ring (30), then remove collar (31).
xvii) Turn over No. 1 carrier assembly, pull out
shaft (33) partially from carrier (32), remove ball (34), then remove shaft (33).
Keep the ball in a safe place and be
careful not to lose it.
30-67
2 "
"
xviii) Remove gear (34) and thrust washer

(35) from carrier.
xix) Remove needle bearing (36) from gear
(34).
6. No. 1 discs, plates, springs

1) Remove 12 springs (37).
2) Remove 6 discs (38), 6 springs (40), and 5
plates (39) in turn, then remove guide plate.
Store the discs and plates in a flat place
to prevent them from becoming deformed.
30-68
"
2 "

7. No. 1 clutch ring gear

Remove No. 1 clutch ring gear (41).
8. No. 1 housing
1) Using eyebolts 5 , remove No. 1 housing assembly (42).
D375A-5
2) Disassemble No. 1 housing assembly as follows.

i) Remove piston (43) from housing (44).


1) Remove 12 springs (47).
2) Remove 6 discs (48), 5 plates (49), and 6
springs (50) in turn.
ii) Remove seal ring (45) from piston (43).

iii) Remove seal ring (46) from housing (44).
3) Remove 17 sleeves (51).
D375A-5
30-69
2 "
"
4) Remove seal ring (52) from No. 2 and No. 3

carrier.
5) Remove 6 torque pins (53).
6) Remove 12 guide pins (54).
2) Disassemble No. 1 ring gear and No. 2, No.

3 carrier assembly as follows.
i) Remove seal rings (57) and (58).
ii) Remove ring (59).
10. No. 1 ring gear, No. 2, No. 3 carrier assembly

1) Using eyebolts 6 , lift off No. 1 ring gear and
No. 2, No. 3 carrier assembly (55).
iii) Pull out shaft (61) partially from carrier

(60), remove ball (62), then remove shaft
(61).
30-70
"

2 "
D375A-5
iv) Remove gear (63) and thrust washer

(64) from carrier.
v) Remove needle bearing (65) from gear
(63).
No. 2, No. 3 carrier (60) and No. 1
ring gear (66) are secured by an internal embedded ring, so they cannot be disassembled.
11. No. 2 ring gear

Remove No. 2 ring gear (67).
D375A-5

12. No. 2, No. 3 housing assembly

1) Using eyebolts 7 , remove No. 2 and No. 3
housing assemblies (68) as one unit with top
and bottom pistons.
Tie the bottom piston with wire to prevent
it from falling out.
2) Disassemble No. 2 and No. 3 housing assemblies as follows.

i) Remove pistons (69) and (70) from
housing (71).
30-71
2 "
"

iii) Remove seal ring (73) from piston (70).


1) Remove guide plate, then remove 12 springs
(76).
plates (78) in turn.
iv) Remove seal rings (74) and (75) from

housing (71).
14. No. 3, No. 4 clutch plate

Using eyebolts 8 , remove plate (80).
30-72
"
2 "
D375A-5

plates (82) in turn, then remove guide plate
(147).
2) Remove 6 torque pins (84).

2) Disassemble No. 4 housing assembly as follows.

i) Remove piston (86) from housing (87).

iii) Remove seal ring (89) from housing (87).
16. No. 4 housing assembly

1) Using eyebolts 9 , remove housing assembly (85) as one unit with piston.
D375A-5
30-73
2 "
"
17. No. 3 ring gear, No. 4 carrier, No. 5 clutch assembly

1) Rotate tool D1, and set transmission facing
sideways.
3) Remove snap ring (91), then remove plate
(92).
4) Remove snap ring (93), then remove spacer

(94).
30-74
"
2 "

5) Set No. 4 carrier end at top and stand transmission assembly.

6) Using eyebolts 0 , sling No. 3 ring gear and
No. 4 carrier, No. 5 clutch assembly (95),
then tap bottom part of output shaft with a
copper hammer and remove.
7) Disassemble No. 3 ring gear and No. 4 carrier, No. 5 clutch assembly as follows.
i) Remove 2 seal rings (56) from housing.
ii) Remove seal ring (118) from input shaft.
D375A-5
iii) Remove snap ring (96), then remove No.

3 sun gear (97).
iv) Remove collar and bearing assembly
(98).
v)

vi) Using eyebolts A , remove No. 3 ring

gear and No. 4 carrier assembly (101) as
one unit with No. 4 sun gear.
vii) Remove No. 4 sun gear (102) from No. 3
ring gear and No. 4 carrier assembly
(101).
Using push tool, remove ball bearing

(99) from collar (100).
viii) Turn over No. 3 ring gear and No. 4 carrier assembly and remove hub (103).
ix) Remove seal rings (104) and (105) from
hub (103).
D375A-5
30-75
2 "
"
x)
Remove snap ring (106), then remove

collar (107) from No. 3 ring gear and No.
4 carrier assembly (101).
xi) Remove seal ring (108) from collar (107).
xii) Pull out shaft (110) partially from carrier

(109), remove ball (111), then remove
shaft (110).
xiii) Remove gear (112) and thrust washer
(113) from carrier.
xiv) Remove needle bearing (114) from gear
(112).
30-76
"
2 "

xv) Turn over carrier (109) and remove snap

ring (115).
xvi) Turn over carrier, then using push tool,
remove ball bearing (116).
No. 3 ring gear (117) and No. 4 carrier (109) are secured by an internal
embedded ring, so they cannot be
disassembled.
xvii) Set output end of output shaft at top, and

put output shaft and housing assembly
(118) on top of block.
xviii) Using forcing screws, disconnect input
shaft and housing assembly (118), then
use eyebolts B to remove.
Tighten the forcing screws uniformly
and disconnect the output shaft and
housing.
D375A-5
xix) Remove 6 discs (119), 6 springs (121),

and 5 plates (120) from housing (122) in
turn.
xx) Set output shaft and housing assembly

to press, then using push tool C , remove housing assembly (123) from output shaft assembly (124).
To prevent the housing assembly
from falling out, set block D under
the housing assembly.
D375A-5

xxi) Set housing assembly (123) to press,

then using tool D2, tighten spring, and
remove snap ring (125).
Operate the press slowly and push
up the springs uniformly.
xxii) Remove retainer (126) and spring (127)
from housing (128).
xxiii) Remove piston (129) from housing, then

remove seal ring (130) from piston (129).
30-77
2 "
"
xxiv)Remove seal ring (131) from housing

(128).
xxv) Remove snap ring (132) from housing.
xxvi)Using push tool, remove ball bearing
(133) from housing.

18. Rear case assembly

1) Remove collar (138) from rear case (139).
2) Remove seal ring (140) from collar (138).
xxvii) Remove snap ring (134), then remove

needle bearing (135) from input shaft
(124).
xxviii)Turn over output shaft, remove snap ring
(136), then remove roller bearing (137)
from output shaft.
3) Turn over rear case, remove snap ring (141),

then remove ball bearing (142).
30-78
"
2 "
D375A-5
ASSEMBLY
Wash all parts clean, dry them (especially the oil
holes), check that there are no scratches or dirt,
then coat the sliding parts with engine oil before
assembling.
Coat each spline portion with grease (G2-LI).

2) Turn over rear case (139) and install to collar

(138).
Be careful not to get the seal ring caught.
1. Preparatory work
Set rear case (139) to tool D1.
3. Output shaft assembly

1) Using push tool, press fit needle bearing
(135) to output shaft (124), then secure with
snap ring (134).
2. Rear case assembly

1) Install seal ring (149) to collar (138).
Install the seal ring in the direction
2) Using push tool, press fit ball bearing (142)

to output shaft.
2 Seal ring: Grease (G2-LI)
D375A-5
30-79
2 "
"
3) Install spacer (94) and secure with snap ring

(93).

8) Install plate (92) and secure with snap ring

(91).
2 Mounting bolt:
3 Mounting bolt:
66.15 7.35Nm {6.75 0.75kgm}
5) Install seal ring (118).
6) Turn over rear case (139) and set output

shaft assembly (124) in position, then using
push tool, press fit bearing portion.
30-80
"
2 "
4. No. 3 ring gear, No. 4 carrier, No. 5 clutch assembly

1) Assemble No. 3 ring gear, No. 4 carrier, and
No. 5 clutch assembly as follows.
When No. 3 ring gear, No. 4 carrier is
supplied as an individual part.
Using tool D3, compress ring (143), then
set No. 3 ring gear (117) on top of No. 4
carrier (109), and tap No. 3 ring gear
(117) with a plastic hammer to assemble.
Check that the ring is fitted securely
in the groove.
D375A-5
i)
Using push tool, press fit ball bearing

(116) to carrier (109), and secure with
snap ring (115).
ii) Turn over carrier.

iii) Assemble needle bearing (114) to gear
(112), then fit thrust washers (113) to
both ends and set carrier in position.
iv) Fit ball (111) and install shaft (110) to
carrier.
Check that the gear rotates smoothly.

v)
Install seal ring (108) to collar (107).

vi) Align collar (107) with dowel pin, then install No. 3 ring gear and No. 4 carrier assembly (101) and secure with snap ring
(106).
Knock in the dowel pin portion with a
plastic hammer until there is no
clearance at the mating surface.
vii) Install seal rings (105) and (104) to hub

(103).
viii) Install hub (103) to No. 3 ring gear and

No. 4 carrier assembly (101).
Be careful not to get the seal ring
caught.
D375A-5
30-81
2 "
"

ix) Using eyebolts E , install housing (122)

to No. 3 ring gear and No. 4 carrier assembly.
xi) Using push tool, press fit ball bearing

(133) to housing (128), and secure with
snap ring (132).
x)
xii) Install seal ring (131) to housing.

Install 6 discs (119), 6 springs (121), and

5 plates (120) in turn.
2 Seal ring:
Grease (G2-LI)
30-82
"
2 "
D375A-5
xiii) Install seal ring (130) to piston (129).

xiv) Install piston (129) to housing (128).

Be careful not to get the seal ring
caught.

xvii) Using eyebolts F , install housing assembly (123).

2 Mounting bolt:
3 Mounting bolt:
176.4 19.6Nm {18 2kgm}
xviii) Install 2 seal rings (56) to housing.
xv) Set spring (127) and retainer (126) to

housing.
Set the 3 springs as shown in the diagram below.
xvi) Set housing assembly (123) to press,
and using tool D2, compress spring, then
install snap ring (125).
Spring installed load:
2,175N {222kg}
D375A-5
2) Turn over rear case (139), and No. 3 ring

gear, No. 4 carrier, and No. 5 clutch assembly (95).
3) Using eyebolts 0 , set No. 3 ring gear, No. 4
carrier assembly, and No. 5 clutch assembly
(95) to rear case and output shaft.
30-83
2 "
"
4) Using push tool G , press fit bearing portion

of No. 3 ring gear, No. 4 carrier, and No. 5
clutch assembly (95) to output shaft.
5. No. 4 sun gear

Install No. 4 sun gear (102).
30-84
"
2 "

6. No. 3 sun gear

1) Using push tool, press fit ball bearing (99) to
collar (100).
2) Install collar and bearing assembly (98).

Install with the flanged side of the collar
at the top.
3) Install No. 3 sun gear (97) and secure with
snap ring (96).
D375A-5

1) Install seal ring (89) to housing (87).

4) Using eyebolts 9 , align dowel pin and install

No. 4 housing assembly (85).
plastic hammer until there is no clearance at the mating surface.
2) Install seal ring (88) to piston (86).


1) Install 6 torque pins (84).
Length of torque pin: 162mm
2) Fit guide plate (147), and install 3 discs (81),
3 springs (83), and 2 plates (82) in turn.
3) Install piston (86) to housing (87).
D375A-5
30-85
2 "
"
9. No. 3, No. 4 clutch plate

Using eyebolts 8 , align plate (80) with dowel pin
and install.
Knock in the dowel pin portion with a plastic
hammer until there is no clearance at the
mating surface.

1) Install 4 discs (77), 3 springs (79), and 3
2) Install 12 guide pins (54).
Length of guide pin: 360mm
3) Fit 12 springs (76) and install guide plate.
Free length of spring: 97mm

11. No. 1 ring gear, No. 3 housing assembly

1) Install seal rings (74) and (75) to housing
(71).


30-86
"
2 "
D375A-5
4) Install pistons (70) and (69) to housing (71).

Tie piston (70) with thin wire to prevent it
from falling out when the housing is
raised.
5) Align dowel pin and install housing assembly

(68).
D375A-5

12. No. 2 ring gear

Install ring gear (67).
13. No. 1 ring gear, No. 2, No. 3 carrier assembly

1) Assemble No. 1 ring gear and No. 2, No. 3
carrier assembly as follows.
When No. 1 ring gear and No. 2, No. 3
carrier is supplied as an individual part.
Using tool D4, compress ring (144), then
set No. 1 ring gear (66) on top of No. 2,
No. 3 carrier (60), and tap No. 1 ring gear
(66) with a plastic hammer to assemble.
in the groove.
30-87
2 "
"
i)
Assemble needle bearing (65) to gear

(63), then fit thrust washers (64) to both
sides and set to carrier (60).

iii) Install ring (59) to carrier.

in the groove.
iv) Install seal rings (58) and (57) to carrier.
Center seal ring (58) with the carrier

and secure in position with grease
(G2-LI).
ii)
Fit ball (62) and install shaft (61) to carrier.

Check that the gear rotates smoothly.
2) Using eyebolts 6 , install No. 1 ring gear and
No. 2, No. 3 carrier assembly (55).
30-88
"
2 "
D375A-5
3) Using push tool H , press fit bearing portion

of No. 1 ring gear and No. 2, No. 3 carrier assembly (55).

3) Install 17 sleeves (51).
Set the sleeve with the slit at the bottom

and install it in the bolt hole marked q.
1) Install 6 torque pins (53).
Length of torque pin:199mm
2) Install seal ring (52) to No. 2, No. 3 carrier.
4) Install 12 springs (47).

Align the notches in the oil groover on the
outside circumference of the discs.
D375A-5
30-89
2 "
"

1) Install seal ring (46) to housing (44).


4) Using eyebolts 5 , align dowel pin and install

housing (42).
Check that the spring is fitted securely in
the hole in the housing.
16. No. 1 clutch ring gear

Install No. 1 clutch ring gear (41).
3) Install piston (43) to housing (44).
30-90
"
2 "
D375A-5

1) Fit guide plate and install 12 springs (37).
18. Input shaft, No. 1 carrier assembly

1) Assemble input shaft and No. 1 carrier assembly as follows.
i) Assemble needle bearing (36) to gear
(34), then fit thrust washers (35) to both
ends and set to carrier (32).
D375A-5

ii)
Fit ball (34) and install shaft (33) to carrier.

iii) Install collar (31) to carrier and secure
with snap ring (30).
iv) Using push tool I , press fit ball bearing

(28) to plate (25), then secure with snap
ring (27).
30-91
2 "
"
v)
Turn over plate and install seal ring

(146).
Align the center of the plate and use
grease (G2-LI) to hold the seal ring in
position.
vi) Install spacer (29) to No. 1 carrier assembly (26).
viii) Using press, install ball bearing (22) to

input shaft assembly (23).
ix) Set housing and No. 1 carrier assembly
(20) to block.
x) Using eyebolts 3 , install input shaft assembly (18) to housing and No. 1 carrier
assembly.
vii) Set plate (25) to No. 1 carrier (26), then

using push tool J , press fit bearing portion and secure with snap ring (24).
xi) Install snap ring (19).
30-92
"

2 "
D375A-5
xii) Set input shaft and No. 1 carrier assembly facing sideways, and install spacer
(17).
xiii) Install No. 1 sun gear (16).

xv) Install spacer and bearing assembly

(12).
Install the small diameter bearing
facing the No. 1 sun gear.
xvi) Install No. 2 sun gear (11) and secure
with snap ring (10).
xiv) Using push tool, press fit ball bearings

(13) and (14) to spacer (15).
xvii) Install seal ring (9) to No. 1 carrier.
Align with the center of the carrier
and use grease (G2-LI) to hold the
seal ring in position.
2) Turn over input shaft and No. 1 carrier assembly (8), then using eyebolts 2 , set to
No. 1 housing.
Check that the tip of the input shaft does
not interfere with the output shaft bearing, and lower slowly.
D375A-5
30-93
2 "
"

3) Tighten 4 tie bolts (12) uniformly on diagonally opposite sides.

4) Tighten remaining bolts (12).
3 Tie bolt:
259.7 14.7Nm {26.5 1.5kgm}
19. Air check

Using tool D5, check stroke of each clutch piston.
Air pressure: 490-588KPa {5-6kg/cm2}
Standard stroke of piston
Piston
Stroke (mm)
30-94
"
2 "
No. 1 No. 2 No. 3 No. 4 No. 5

6.7
7.0
5.6
4.7
7.0
20. Front case

Fit O-ring and use eyebolts to install front case
(6).
Check that the front case does not interfere
and lower gradually.
21. Output shaft bearing

1) Set output shaft end at top and stand transmission assembly.
2) Using push tool, press fit roller bearing (137)
to output shaft, and secure with snap ring
(136).
Be careful not to hit or damage the bearing cage or roller.
Use a push tool of a size that pushes
only the outer race.
D375A-5
22. Lubrication valve assembly

Install lubrication valve assembly (5).


Remove plug (145) and check that the
linkage pin on the inside of the cover is
meshed with the yoke of the control valve
spool.
After checking, install plug (145).
3) Fit O-ring and install sleeve, then install cover (2).
4) Install tube.

1) Install control valve assembly (4) as one unit
with seat.
3 Mounting bolt:
49.0 4.9Nm {5.0 0.5kgm}
D375A-5
30-95
2 "
"
DISASSEMBLY AND ASSEMBLY OF STEERING

CASE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF STEERING
CASE ASSEMBLY
DISASSEMBLY
1. Steering control valve assembly
1) Remove steering control valve assembly (1).
4
Steering control valve assembly:

25kg
iii) Using forcing screws 1 , remove sleeve

(7).
iv) Using puller 2 , pull out bearing inner
race (8) from sleeve.
2) Remove seat (2).

2. Clutch, brake assembly
1) Using eyebolts, sling clutch and brake assembly, then remove mounting bolts, and remove clutch and brake assembly (3).
Remove the clutch and brake assembly
on the opposite side in the same way.
When pulling out the clutch and brake
assembly, be careful not to damage the
discs and plates.
v)
Turn over clutch and brake assembly,

then using eyebolts 3 , disconnect
clutch assembly (9) and brake assembly
(10).
2) Disconnect clutch and brake assembly as

follows.
i) Remove plate (4), then remove collar (5).
ii) Remove plate (6).
30-96
"
2 "
D375A-5
3) Disassemble clutch assembly as follows.

i) Remove stopper (11).
ii) Remove discs (12), springs (13), and
iii) Remove torque pin (15).

iv) Using eyebolts, remove clutch hub (16).
v) Using forcing screws 4 , remove plate
(17).
D375A-5

CASE ASSEMBLY
vi) Remove outer race (18) from plate.

vii) Remove bearing and cage assembly
(19).
viii) Remove plate (21) and nut (22) from

cage (20).
ix) Remove bearing and inner race (23),
spacers (24) and (25), and bearing outer
race (26).
30-97
2 "
"
x)
xi)
xii)
xiii)
Using eyebolts, remove clutch cage (27).

Remove seal ring (28) from clutch cage.
Remove piston (29).
Remove seal ring (30) from piston.
xiv) Remove bearing outer race (31) from

clutch cage.
xv) Remove belleville spring (32).
30-98
"
2 "

CASE ASSEMBLY
xvi) Using eyebolts 6 , remove brake hub

(33).
xvii) Remove bearing (34) from brake hub.
4) Disassemble brake assembly as follows.

i) Remove stopper (35).
ii) Remove discs (36), springs (37), and
D375A-5
iii) Using eyebolts 7 , remove brake cage

(39).
iv) Remove bearing outer race (40) and seal
ring (41) from brake cage.
v) Remove torque pin (42).

vi) Remove piston (43).
vii) Remove seal ring (44) from piston.

CASE ASSEMBLY
3. Shafts
Remove left and right shafts (46).
4. Lubrication tube
Remove lubrication tube (47).
5. Pipes
1) Remove left and right pipes (48).
2) Remove pipe (49).
viii) Remove belleville spring (45).
D375A-5
30-99
2 "
"
6. Transfer, gear housing assembly

1) Fit guide bolt 8 , raise with eyebolts 9 , then
remove housing assembly (50).
2) Disassemble transfer gear housing assembly as follows.
i) Set transfer gear housing assembly on
block.
ii) Remove lubrication tube (51).
iii) Using push tool, remove bearing (53).

iv) Remove drive gear (54).
30-100
"
2 "

CASE ASSEMBLY
Using puller 0 , remove both bearing inner races (55).

vi) Remove lubrication tube (56).
v)
vii) Using eyebolts A , remove pinion housing assembly (57).

Check the number and thickness of
the shims, and keep in a safe place.
viii) Using forcing screws, remove cover (58).
ix) Remove holder (59).
D375A-5
x)
Push pinion shaft with press, then pull

out pinion gear (60).
xi) Remove holder, then using puller B , remove bearing inner race (61) from pinion
gear (60).
xii) Remove cage and bearing assembly
(62).
xiii) Remove collar (63) from gear (64).

xiv) Using push tool C , remove bearing outer races (65) and (69), bearing inner races (66) and (67), and collar (68).
D375A-5

CASE ASSEMBLY
xv) Remove bearing (70) from case.

xvi) Remove bearing (71) from case.
7. Right cage
1) Turn over steering case so that right cage is
at top.
2) Remove cage and bearing assembly (72).
3) Remove bearing outer race from cage and
bearing assembly.
4) Using eyebolts D , remove cage (73).
30-101
2 "
"
8. Bevel gear, shaft assembly

1) Using eyebolts, remove bevel gear and shaft
assembly.
2) Disassemble bevel gear and shaft assembly
as follows.
i) Pull out reamer bolt, then remove bevel
gear (75) from shaft (76).

CASE ASSEMBLY
2) Remove bearing outer race (80) from cage

and bearing assembly.
ASSEMBLY
ii)
Using puller E , remove bearing inner

races (77) and (78) from shaft.
9. Left cage
1) Turn over steering case so that left side of
steering case is at top, then remove cage
and bearing assembly (79).

Coat the rotating portion of the bearing with engine oil and rotate it several times.
Coat the sliding parts with engine oil, then assemble.
groove.
1. Left cage
(80).
2) Assemble shims, and install cage and bearing assembly (79).
3 Cage, bearing assembly mounting
bolt: 176.4 19.6Nm {18 2kgm}
30-102
"
2 "
D375A-5
2. Bevel gear, shaft assembly

1) Assemble bevel gear and shaft assembly as
follows.
i) Using push tool F , press fit bearing inner races (78) and (77).
ii) ii) Set bevel gear (75) to shaft (76) and
tighten reamer bolt.
3 Reamer bolt:
274.4 29.4Nm {28 3kgm}

CASE ASSEMBLY
2) Assemble shim and install cage and bearing

assembly (72).
3 Cage, bearing assembly mounting
bolt:
176.4 19.6Nm {18 2kgm}
2) Using eyebolts, install bevel gear and shaft

assembly (74).
3. Right cage
1) Using eyebolts D , install cage (73).
4. Adjusting preload
Adjust shim thickness at cage to adjust rotating
force of bevel gear shaft.
Rotate the bevel gear 2 - 3 times and put the
push-pull scale in contact with the tip of the
tooth.
Rotating force (with bevel gear not meshed):
4.9 - 5.88 N {0.5 - 0.6 kg}
(Rotating torque: 23.52 - 28.42 Nm
{2.4 - 2.9 kgm})
D375A-5
30-103
2 "
"
5. Transfer, gear housing assembly

1) Assemble transfer and gear housing assembly as follows.
i) Using push tool F , press fit transfer
gear bearing (71) to case.
ii) Using push tool G , press fit pinion bearing (70) to case.
iii) Using push tool, press fit bearing outer

race (69) to cage.
iv) Assemble bearing inner races (67) and
(66) and collar (68).
v) Using push tool, press fit bearing outer
race (65).
30-104
"
2 "

CASE ASSEMBLY
vi) Using push tool H , press fit inner race

(61) to pinion gear (60).
vii) Install holder.

276.85 31.85Nm {28.25 3.25kgm}
viii) Install gear (64) and collar (63) to pinion

gear.
ix) Using push tool I , press fit cage and

bearing assembly (62).
x) Install holder (59).

276.85 31.85Nm {28.25 3.25kgm}
D375A-5
xi) Tighten mounting bolts of cover (58) in

the order given in diagram and to tightening torque given below, and temporarily
assemble cover (58).
3 Mounting bolt: 49Nm {5kgm}
xii) Check clearance A between cover and

cage, and check that it is as given below.
Clearance A : 0.48 0.27mm
Check that the variation around the
whole circumference is less than
0.05 mm and that the bearing is
completely press fitted and is not at
an angle.
D375A-5

CASE ASSEMBLY
xiii) Tighten mounting bolts of cover (58) in

order given in diagram.
3 Mounting bolt:
66.15 7.35Nm {6.75 0.75kgm}
xiv) Assemble shims to pinion housing assembly (57), then use eyebolts A to install.
xv) Install lubrication tube (56).
30-105
2 "
"
xvi) Using push tool J , press fit bearing inner race (55) to both sides of drive gear.
xvii) Set drive gear (54) to case.

CASE ASSEMBLY
2) Fit guide bolt 8 to steering case, then using

eyebolts 9 , install transfer and gear housing
assembly (50).
3 Mounting bolt:
276.85 31.85Nm
{28.25 3.25kgm}
6. Lubrication tube
Install lubrication tube (47).
xviii) Using push tool K , press fit bearing

(53).
xix) Install bearing assembly (52) to case.
xx) Install lubrication tube (51) as one unit
with block.
7. Adjusting backlash, tooth contact

1) Adjusting backlash
Testing
Put the probe of dial gauge L in contact with
the tooth face at the tip of the bevel gear, fix
the bevel pinion in position, and read the
scale when the bevel gear is moved backward and forward.
Standard value of backlash:
0.3-0.4mm
Measure at 3 places on diametrically opposite sides.
30-106
"
2 "
D375A-5
Adjusting
If the result of the measurement shows that
the backlash is not correct, adjust as follows.
i) When backlash is too small:
Adjust the shim thickness at the bevel
pinion end and move the bevel pinion in
direction A.
Or, adjust the shim thickness at the bearing cage of the bevel gear shaft and
move the bevel gear in direction B.

CASE ASSEMBLY
2) Adjusting tooth contact

Testing
i)
Coat the tooth face of the bevel pinion

lightly with red lead (minium), then rotate
the bevel gear forward and backward
and inspect the pattern left on the teeth.
ii)
ii)
When backlash is too large:

direction C.
move the bevel gear in direction D.
When adjusting the shim thickness at the
bearing cage of the bevel gear shaft, do
not change the preload of the bearing.
Adjust by moving shims from one side to
the opposite side. Always keep the
same total thickness of shims.
D375A-5
The standard value for the tooth contact

is as follows
(from small end of pinion)
a) Width of tooth contact: 30 - 75 %
b) Center of tooth contact: 25 - 50 %
c) Position of tooth contact: 25 - 50 %
When preload is applied to the taper roller bearing supporting the bevel gear, it
should be within the standard value with
only the bevel pinion meshed and under
no load.
The tooth contact should be at the center
of the tooth height and there should be
no strong contact at the root of the gear
tooth.
In addition, the contact should be more
or less the same for forward and reverse.
30-107
2 "
"
Adjusting
If the result of the inspection shows that the
correct tooth contact is not being obtained,
adjust again as follows.
i) When bevel pinion is too far from center
line of bevel gear:
Contact is at the small end of the convex
tooth face of the bevel gear and at the big
end of the concave tooth face.
[Adjusting]
direction A.
move the bevel gear in direction B.
After adjusting, check the tooth contact
pattern and backlash again.

CASE ASSEMBLY
ii)
When bevel pinion is too close to center

of bevel gear:
Contact is at the big end of the convex
tooth face of the bevel gear and the small
end of the concave tooth face.
[Adjusting]
Follow the same procedure as in Step i)
but move the bevel pinion in direction A
and the bevel gear in direction B.
When adjusting the movement in and out
of the bevel gear, do not change the preload of the bearing. Adjust by moving
shims from one side to the opposite side.
Always keep the same total thickness of
shims.
8. Pipes
1) Install pipe (49).
2) Install left and right pipes (48).
30-108
"
2 "
D375A-5
9. Clutch, brake assembly

1) Assemble brake assembly as follows.
i) Install belleville spring (45).
Install the belleville springs back to
back.
ii) Install seal ring (44) to piston (43).
iii) Install piston (43).

iv) Install torque pin (42).
v) Using push tool, install seal ring (41) and
bearing outer race (40) to brake cage.

CASE ASSEMBLY
vi) Using eyebolts 7 install brake cage (39).

3 Mounting bolt:
110.25 12.25Nm {11.25 1.25kgm}
vii) Install plates (38), springs (37), and

discs (36).
Check that there is no dirt or damage
to the mating faces of the discs and
plates, and coat thinly with engine oil
before assembling.
viii) Install stopper (35).
3 Mounting bolt:
276.85 31.85Nm {28.25 3.25kgm}
2) Assemble clutch assembly as follows.

i) Using push tool, install bearing (34) to
brake hub.
D375A-5
30-109
2 "
"
Using eyebolts 6 , install brake hub (33)

to clutch housing.
iii) Install belleville spring (32).
Install the belleville springs back to
back.
ii)

CASE ASSEMBLY
ix) Install bearing inner race (26), spacers

(25) and (24), and bearing inner race
(23) to cage (20).
x) Tighten nut (22), and install plate (21).
Use a push tool, hold the cage in a
press, and use a hook wrench to
tighten the nut.
iv) Install outer race (31) to clutch cage.

v) Install seal ring (30) to piston.
vi) Install piston (29).
vii) Install seal ring (28) to clutch cage.

viii) Using eyebolts, install clutch cage (27) to
housing.
30-110
"
2 "
D375A-5
xi) Install bearing and cage assembly (19).

xii) Using push tool, install outer race (18) to
plate.

CASE ASSEMBLY
xvii) Install plates (14), springs (13), and

discs (12) in turn.
Check that there is no dirt or damage
to the mating faces of the discs and
plates, and coat thinly with engine oil
before assembling.
xviii) Install stopper (11).
3 Mounting bolt:
276.85 31.85Nm
{28.25 3.25kgm}
xiii) Install plate (17).
3 Mounting bolt:
110.25 12.25Nm {11.25 1.2kgm}
xiv) Set guide bolt to housing.

xv) Using eyebolts, install clutch hub (16).
Check that the rotating force of the
housing is less than 29.4N {3 kg} and
that it rotates smoothly.
xvi) Install torque pin (15).
D375A-5
3) Connect clutch and brake assembly as follows.

i) Using eyebolts C , install brake assembly (10) to clutch assembly (9).
ii) Using push tool D , press fit bearing inner race (8) to sleeve.
30-111
2 "
"
iii) Set sleeve (7) to clutch and brake assembly.

CASE ASSEMBLY
10. Shafts
Install left and right shafts (46).
If the bevel gear is locked in position and it is
difficult to insert the shaft, release the steering brake before inserting.
Remove plug (81), then remove mounting
bolt (82), and screw the mounting bolt into
the plug hole to compress the clutch spring
and release the brake.
iv) Install plate (6).
3 Mounting bolt:
110.25 12.25Nm
{11.25 1.25kgm}
v) Fit collar (5) and install plate (4).

4) Using eyebolts, install clutch and brake assembly.
3 Mounting bolt: 276.85 31.85Nm
{28.25 3.25kgm}
11. Steering control valve

1) Install seat (2).
2) Raise steering control valve assembly (1)
and install.
3 Mounting bolt:
30-112
"
2 "
49.0 4.9Nm
{5.0 0.5kgm}
D375A-5
REMOVAL AND INSTALLATION OF POWER TRAIN,

LUBRICATION PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF POWER
TRAIN, LUBRICATION PUMP
ASSEMBLY
REMOVAL
1. Remove power train underguard (front).
4
Power train underguard (front): 280kg
3. Disconnect tube (2).

4. Lift off power train and lubrication pump assembly (3).
4
Power train, lubrication pump assembly:

50kg
INSTALLATION
D375A-5
30-113
2 "
"
REMOVAL AND INSTALLATION OF SCAVENGING

PUMP ASSEMBLY
REMOVAL AND INSTALLATION OF SCAVENGING PUMP

ASSEMBLY
REMOVAL
1. Remove power train underguard (front).
4
Power train underguard (front): 280kg
2. Disconnect inlet tube (1).

The oil in the piping will leak out, so use a
container to catch it.
3. Disconnect outlet tube (2).
4. Remove scavenging pump assembly (3).
INSTALLATION
Refilling with oil (power train case)

Run the engine to circulate the oil through the
system. Then check the oil level again.
30-114
"
2 "
D375A-5
REMOVAL AND INSTALLATION OF FINAL DRIVE

ASSEMBLY
REMOVAL AND
INSTALLATION OF FINAL
DRIVE ASSEMBLY
5. Remove 3 bolts of final drive, and install tool J1.
SPECIAL TOOLS
Symbol
J
Part No.
1 790-337-1001
Part name

model
cessity
Lifting tool
6. Sling final drive assembly (5), then remove

mounting bolts and lift off.
q2
4
Final drive assembly: 2,300kg
REMOVAL
1. Remove track shoe assembly. For details, see
REMOVAL OF TRACK SHOE ASSEMBLY.
2. Raise chassis with jack or ripper, then set stand
1 under frame.
INSTALLATION
q1
4. Remove cover (3), then using eyebolts, pull out

q1
drive shaft (4).
If the shaft does not come out, push up the
shoe grouser from the ground surface with a
jack and move the sprocket backwards or
forwards to adjust to a position where the
shaft can be removed, then pull the shaft out.
Pull the shaft out to a point where it contacts
the sprocket.
If the shaft does not go in, push up the shoe

grouser from the ground surface with a jack
and move the sprocket backwards or forwards to adjust to a position where the shaft
meshes, then assemble the shaft.
q2
2 Final drive assembly mounting bolt:

3 Final drive assembly mounting bolt:
1,720 190Nm {175 20kgm}
Refilling with oil (final drive case)

D375A-5
(SAE 30CD)
Final drive case: 65
30-115
2 "
"
DISASSEMBLY AND ASSEMBLY OF FINAL

DRIVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF FINAL
DRIVE ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.

model
cessity
"
Puller
(294 kN
{30 ton})
"
790-101-1102
Pump
"
791-580-3300
Installer
"
3 790-101-2102
Puller
(294 kN
{30 ton})
"
Pump
"
Installer
"
Remover
"
Puller
(294 kN
{30 ton})
"
790-101-1102
Pump
"
791-580-3500
Installer
"
6 790-101-2102
Puller
(294 kN
{30 ton})
"
790-101-1102
Pump
"
790-431-1230
Remover
& installer
"
790-101-2102
Puller
(294 kN
{30 ton})
"
790-101-1102
Pump
"
8 790-431-1250
Guide
"
2 790-101-2102
790-101-1102
4 790-431-1071
791-580-3400
5 790-101-2102
30-116
!
Part name
Remover
791-580-3200
DISASSEMBLY
2 !
4
1. Draining oil
Remove drain plug and drain oil from final drive
case.
6
Final drive case: Approx.61
2. Sprocket
1) Set final drive assembly to block (height: approx. 50 mm).
2) Remove sprocket (1).
3. Cover
Using eyebolts 1 , remove cover (2).
D375A-5
4. Hub
2) Using eyebolts 2 , lift off hub (4).

DRIVE ASSEMBLY
2) Using tool J2, disconnect sprocket hub assembly (6) and bearing (7).
3) Using eyebolts 3 , remove sprocket hub assembly (6).
5. Sprocket hub assembly

1) Remove holder (5).
4) Remove bearing inner race (8) from sprocket

hub assembly.
D375A-5
30-117
2 "
"
5) Turn over sprocket hub assembly, and remove floating seal cover (9) and bearing outer races (10) and (11).
6) Remove floating seal (12) from floating seal
cover.
Be careful not to damage the floating
seal and keep it in a safe place.
6. Wear guard
Lift off wear guard (13).

DRIVE ASSEMBLY
2) Disassemble cover assembly as follows.

i) Remove floating seal cover (15).
ii) Remove floating seal (16) from floating
seal cover.
Be careful not to damage the floating
seal and keep it in a safe place.
iii) Remove spacer (17) and bearing inner

race (18).
7. Cover assembly
1) Using eyebolts 4 , lift off cover assembly
(14).
30-118
"
2 "
D375A-5
iv) Remove plate, then remove ring gear

(19).
8. Carrier assembly
1) Using eyebolts 5 , remove carrier assembly
(20).

DRIVE ASSEMBLY
iv) Remove planetary gear (23), bearing inner races (24A) and (24B), and spacer
(24C).
v)
Remove bearing outer race (24D).
2) Disassemble carrier assembly as follows.

i) Set carrier assembly to block (approx.
100mm).
ii) Remove holder (21).
iii) Using tool J7, remove planetary gear
shaft (22).
9. Sun gear
1) Remove plate (25), button (26), and sun gear
(27).
D375A-5
30-119
2 "
"
10. Hub, shaft assembly


DRIVE ASSEMBLY
3) Disassemble hub assembly as follows.

i) Remove gear (32) from hub (33).
ii) Remove hub (33) from boss (34).
iii) Using puller, remove bearing outer race
(35) from boss (34).
2) Using tool J5, pull out hub assembly (29) and

bearing inner race (30) from shaft assembly
(31).
4) Using eyebolts 6 , pull out shaft assembly
(31) from case.
5) Disassemble shaft assembly as follows.
i) Remove collar (36).
ii) Remove bearing inner race (37) and collar (38).
30-120
"
2 "
D375A-5
11. Cage assembly

1) Using eyebolts 7 , remove cage assembly
(39).
2) Remove shims (40).
3) Disassemble cage assembly as follows.

i) Using puller 8 , remove bearing outer
race (41).
ii) Remove oil seals (42) and (43).
D375A-5

DRIVE ASSEMBLY
12. Gear assembly

1) Remove gear assembly (44).
2) Using puller 9 , remove bearing inner races
(45) and (46) from gear.
13. Outer race, oil seals

1) Using puller 0 , remove bearing outer race
(48).
2) Remove oil seals (49) and (50) from case.
30-121
2 "
"
ASSEMBLY
Wash all parts clean, check that there are no
dents or dirt, then coat the sliding parts with engine oil before assembling.

DRIVE ASSEMBLY
2) Using push tool C , press fit bearing outer

race (48).
1. Oil seals, bearing outer race

1) Using push tools A and B , install oil seals
(50) and (49).
Install the bottom seal with the side receiving the pressure at the bottom and
the top seal with the side receiving the
pressure at the top.
2 Press-fitting surface of oil seal:

Coat the inside surface of the case thinly
with gasket sealant and wipe off any
sealant that is squeezed out.
30-122
"
2 "
2. Gear assembly
1) Using push tool D , press fit bearing inner
races (46) and (45) to gear.
2) Set tool J8 to case, and install gear assembly (44).
Leave tool J8 in position. (Remove it after installing the cage.)
D375A-5

DRIVE ASSEMBLY
3. Cage assembly
1) Assemble cage assembly as follows.
i) Using push tools A and B , install oil
seals (43) and (42).
Install the bottom seal with the side
receiving the pressure at the bottom
and the top seal with the side receiving the pressure at the top.
ii)
Using push tool E , press fit bearing outer race (41).
2 Lip of oil seal:
Grease (G2-LI)
2 Press-fitting surface of oil seal:

Coat the inside surface of the case
thinly with gasket sealant and wipe
off any sealant that is squeezed out.
2) Using eyebolts 7 , set cage assembly (39)
to case, then tighten portions C and D uniformly with mounting bolts.
3 Mounting bolt: 14.7Nm {1.5kgm}
D375A-5
30-123
2 "
"

DRIVE ASSEMBLY
3) In this condition, use thickness gauge F as

shown in the diagram below and measure
clearances a and b between cage A and
case B.
4) Use table to set thickness c of shim to insert.
5) Assemble shims selected in Step 4), then
tighten 4 cage mounting bolts.
From
Less
than
1.6
1.8
1.8
2.0
227.3 80.85Nm
{23.25 8.25kgm}
2.0
Rotate the gear and tighten uniformly,

then remove tool J8.
3 Mounting bolt:
30-124
"
a + b [mm]
2 "
No. of shims to use

t = 0.1
t = 0.5
Total shim
thickness
t = 1.0
c [mm]
1
1.0
1.1
2.2
1.2
2.2
2.4
1.3
2.4
2.6
1.4
2.6
2.8
1.5
2.8
3.0
1.6
3.0
3.2
1.7
3.2
3.4
1.8
3.4
3.6
1.9
3.6
3.8
2.0
3.8
4.0
2.1
4.0
4.2
2.3
4.2
4.4
2.3
4.4
4.6
2.4
4.6
4.8
2.5
4.8
5.0
2.6
5.0
5.2
2.7
5.2
5.4
2.8
5.4
5.6
2.9
5.6
5.8
3.0
D375A-5
4. Hub, shaft assembly

1) Assemble shaft assembly as follows.
i) Install collar (38).
ii) Using push tool (17), press fit bearing inner race (37).
iii) Install collar (38).

DRIVE ASSEMBLY
ii) Set boss (34) to hub (33).

4) Set shaft assembly (31) and hub assembly
(29) in position, then using tool J6, press fit
bearing portion (30).
5) Tighten mounting bolts of hub assembly

(29).
2) Using eyebolts 6 , install shaft assembly
(31) to case.
3) Assemble hub assembly as follows.
i) Using push tool, press fit bearing outer
race (35) to boss (34).
3 Mounting bolt:
276.85 31.85Nm
{28.25 3.25kgm}
2 Mounting bolt:
3 Mounting bolt:
548.8 58.8Nm {56 6kgm}
7) Install gear (32).
3 Mounting bolt:
539 49Nm {55 5kgm}
D375A-5
30-125
2 "
"
5. Sun gear
1) Install sun gear (27) to hub assembly.
2) Install button (26) and plate (25).
i)
Install ring and spacer to planetary gear,

then using push tool H , press fit top and
bottom bearing outer races (24D).
6. Carrier assembly
1) Assemble carrier assembly as follows.
The bearing for the planetary gear consists of a set, so match the distinguishing
marks on the inner race, outer race, and
spacer when assembling.
q1.Distinguishing mark for bearing
q2.Distinguishing mark for bearing
spacer
ii)
Assemble spacer (24C) and bearing inner races (24B) and (24A) to planetary
gear (23), and set to carrier.
30-126
"

DRIVE ASSEMBLY
2 "
D375A-5
iii) Using tool J7, press fit planetary gear

shaft (22).
Align the bearing and spacer hole,
then gradually press fit the shaft.
iv) Install holder (21).

DRIVE ASSEMBLY
Using tool J3, press fit bearing inner race

(18).
iii) Install spacer (17).
ii)
3 Mounting bolt:
548.8 58.8Nm {56 6kgm}
After tightening the bolts, check that

the gear rotates smoothly.
2) Using eyebolts 5 , install carrier assembly

(20).
iv) Using tool J4, press fit floating seal (16)

to floating seal cover.
Remove all oil and grease from the
O-ring and O-ring contact surface,
and dry before installing.
After installing the floating seal,
check that the angle of the seal is
less than 1 mm.
7. Cover assembly
1) Assemble cover assembly as follows.
i) Fit ring gear (19), and install plate.
Install the plate so that the chamfered side is at the top.
D375A-5
30-127
2 "
"
v)
Install floating seal cover (15).

Fit a cork plug in the forcing tap.

DRIVE ASSEMBLY
2) Using eyebolts 4 , raise cover assembly

(14) and install.
Coat the mating faces with Three Bond
1216.
8. Wear guard
Raise wear guard (13) and install.
Install the floating seal cover with the

notch facing down as shown in the
diagram below.
9. Sprocket hub assembly
1) Using tool J4, install floating seal (12) to
floating seal cover.
Remove all oil and grease from the Oring and O-ring contact surface, and dry
before installing.
After installing the floating seal, check
that the angle of the seal is less than 1
mm.
30-128
"
2 "
D375A-5
2) Using push tool, press fit bearing outer races

(11) and (10).
3) Install floating seal cover (9).

DRIVE ASSEMBLY
5) Using eyebolts 3 , sling sprocket hub assembly (6) and set to cover.
Check that there is no dirt on the sliding
surface of the floating seal, then coat
thinly with engine oil.
4) Set bearing (8) to sprocket hub assembly.

6) Using tool J3, press fit bearing portion (7).
Rotate the sprocket hub assembly while
press fitting.
D375A-5
30-129
2 "
"
7) Install holder (5).
2 Mounting bolt:
3 Mounting bolt:

DRIVE ASSEMBLY
11. Cover
Using eyebolts 1 , install cover (2).
276.85 31.85Nm
{28.25 3.25kgm}
12. Sprocket
Install sprocket (1).
2 Mounting bolt:
10. Hub
1) Using eyebolts 2 , lift off hub (4).
3 Mounting bolt:
1,813 98Nm {185 10kgm}
13. Refilling with oil
Tighten drain plug and add engine oil through oil
filler to the specified level.
5 Final drive case: Approx. 61
Carry out the final check of the oil level after

installing the final drive assembly to the
chassis, and check that the oil is at the specified level.
30-130
!
2 !
4
D375A-5
REMOVAL AND INSTALLATION OF TRACK

FRAME ASSEMBLY
REMOVAL AND
INSTALLATION OF TRACK
FRAME ASSEMBLY
REMOVAL
1. Expand the track shoe assembly. For details,

see EXPANDING TRACK SHOE ASSEMBLY.
2. Raise the machine body with a jack or the ripper

and set stands 1 under the frame to float the
rear part of the machine body.
3. Set hydraulic jack 2 under the center of the
equalizer bar to float the front part of the machine body.
4. Sling the track frame assembly temporarily.
8. Apply a pad to pin (6) from rear and drive out the
pin with a hammer.
If the equalizer bar hole and track frame hole
are not aligned, the pin cannot be removed
easily. Adjust the hanging height of the track
frame properly.
5. Loosen front bolt (1) and rear bolt (2).
9. Remove the mounting bolts and cover (7) from

the track frame.
D375A-5
30-131
2 "
"
REMOVAL AND INSTALLATION OF TRACK

FRAME ASSEMBLY

For the right track frame, disconnect the 4
hoses for the blade tilt cylinder from the cover.
11. Remove seal (9) and washer (10) together.
Perform this procedure for only the right track
frame.
12. Remove washer (11) and spacer (12).
INSTALLATION
2 Inside surface of bushing : Grease (G2-LI)

Before installing the pin, adjust the height of the
track frame and align the center of the equalizer
bar hole and track frame hole.
Set the pin with the grease hole facing the outside of the machine.
Fit pin (4) and bushing (3), install cover (2), then
install the cover and cushion.
After removing the grease from the press fitting
surface of the seal, coat with gasket sealant (LG6).
Be careful not to install with the seal displaced in
the direction of twisting.
Be careful not to install the track frame with seal
(14) displaced in the direction of twisting.
13. Lift off track frame assembly (13).

Receive the oil flowing out of the pivot case
6
30-132
"
2 "
Refilling with oil (pivot case)

Pivot case : 18 (SAE30)
Pivot case: 18
Track frame: 7,260 kg
D375A-5

IDLER ASSEMBLY
REMOVAL AND
INSTALLATION OF
IDLER ASSEMBLY
REMOVAL
INSTALLATION

REMOVAL OF TRACK SHOE ASSEMBLY
To prevent danger, never stand in front of the
idler yoke assembly.
2. Remove scraper (1).

Remove the inside scraper also.
Remove the inside cover also.

For both the left and right idler assemblies,
install with the oil filler plug facing the left
side of the machine.
Tighten the idler cap mounting bolts in the
following order.
Tightening order: 1) 2 bolts at a
2) 2 bolts at b
3) 2 bolts at a
4) Tighten all bolts to
specified torque.
2 Mounting bolt:
3 Mounting bolt :
1641.5 171.5 Nm
{167.5 17.5 kgm}
After tightening the idler cap mounting bolts,
check that clearance c between the bottom
of the idler cap and the yoke is 0.
4. Sling idler assembly and remove idler cap (3).
For both the left and right idler assemblies,
there is a ball assembled to the left idler cap,
so keep it in a safe place and be careful not
to lose it.
5. Lift off idler assembly (4).
4
D375A-5
Idler assembly : 478 kg
30-133
2 "
"

IDLER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
IDLER ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.
4. Turn over idler assembly (1).

Part name

model
cessity
791T-630-2210
Plate
792-530-1630
Stud
790-101-2510
Block
790-101-2570
Washer
Nut
Washer
790-101-2102
Puller
(294kN
{30ton})
790-101-1102
1 01580-01613
01643-31645
L
Pump
2 791-515-1520
Installer
3 791-685-8310
Push tool
4 791-601-1000
Oil pump
"
5. Remove mounting bolts, then using eyebolts 3 ,

remove shaft (5) as one unit with retainer.
6. Using puller 4 , remove seal guides (2) and (6),
and plate (8).
DISASSEMBLY
1. Remove oil filler plug and drain oil.
6
Idler: 0.95 - 1.05
7. Remove seal guides (2) and (6) from retainers

(3) and (7).
2. Set idler assembly (1) on blocks 1 .

3. Remove mounting bolts, then using forcing
screws 2 , remove seal guide (2) as one unit
with retainer (3) and plate (4).
30-134
"
2 "
D375A-5
8. Remove floating seal (9) from seal guides (2)

and (6).
Be careful not to damage the floating seal
and keep it in a safe place.
9. Remove floating seal (10) from seal guides (3)
and (7).
Be careful not to damage the floating seal
and keep it in a safe place.

IDLER ASSEMBLY
ASSEMBLY
1. Set bushing (11) and tool L1 to idler (12), and
press fit bushing (11).
First, use a plastic hammer to center the
bushing, then press fit it with a puller.
Press fit the bushing so that press-fitting dimension a from the end face of the idler to
the top face of the bushing is the dimension
below.
Press-fitting dimension a: 17 0.5 mm
10. Remove bushing (11) from idler (12).
2. Using tool L2, install floating seal (10) to retainers (3) and (6).
3. Fit O-ring and install retainer (3) and plate (4) to
idler.
Check that the plate rotates smoothly by
hand.
D375A-5
30-135
2 "
"
4. Using eyebolts 3 , set idler (12) to shaft (5).

Set block (approx. 140 mm) under the idler.
5. Turn over idler assembly.
Tie the shaft with wire to prevent it from falling out.

IDLER ASSEMBLY
8. Set seal guide (2) to shaft, then using tool L3,

press fit seal guide (2).
Press-fitting force of seal guide:
43 - 71 kN {4.4 - 7.2 ton})
6. Fit O-ring and install retainer (7) and plate (8) to

idler.
7. Using tool L2, install floating seal (8) to seal

guides (2) and (6).
30-136
"
2 "
Press fit the seal guide so that press-fitting

dimension b from the end face of the shaft to
the top face of the seal guide is the dimension below.
Press-fitting dimension b: 102 0.2 mm
Turn over the idler assembly and repeat the
procedure above to press fit seal guide (6)
on the opposite side.
D375A-5

IDLER ASSEMBLY
9. Using tool L4, charge with specified amount of

oil, then tighten oil filler plug.
6
Idler: 0.95 - 1.05
3 Oil filler plug:

206 49 Nm {21 5 kgm}
D375A-5
30-137
2 "
"

IDLER ASSEMBLY
SKETCH OF SPECIAL TOOL

Note: We will not be liable for any result caused by a special tool made according to this drawing.
L1 Plate
30-138
"
2 "
D375A-5
REMOVAL AND INSTALLATION OF RECOIL

SPRING ASSEMBLY
REMOVAL AND
INSTALLATION OF RECOIL
SPRING ASSEMBLY
SPECIAL TOOLS
Symbol
M
Part No.
Part name

model
cessity
791-730-1110
Bolt
01580-12722
Nut
6. Remove covers (4).

Remove both the inside and outside covers.
REMOVAL
REMOVAL OF TRACK SHOE ASSEMBLY.
To prevent danger, never stand in front of the
idler yoke assembly.
2. Drain oil from recoil cylinder chamber using oil
pump.
6
Recoil cylinder chamber : Approx. 50
3. Using eyebolt 1 , remove cover (1).

4
Cover : 40 kg

5. Lift off trunnion (3).
4
D375A-5
7. Using tool M1, remove pins (5).

Remove both the inside and outside pins.
Trunnion : 75 kg
8. Lift off idler and recoil spring assembly (6).

Using a lever block, keep the assembly horizontal, and be careful not to damage the oil
seal at the track frame end.
4
Idler, recoil spring assembly : 2,180 kg
30-139
2 "
"

SPRING ASSEMBLY
9. Disconnect recoil cylinder assembly (8) from

idler yoke assembly (7) as follows.
1) Pit idler yoke assembly (7) in contact with
ground, then raise recoil cylinder assembly
(8).
When doing this, check that there is no
damage to the weld of recoil cylinder assembly (7).
Wrap cloth around the chrome plated
bushing to protect it.
2) Loosen idler yoke mounting bolts (9) gradually in turn on diagonally opposite sides.
To prevent danger, never stand in front of
the idler yoke assembly.
The recoil spring inside the recoil cylinder is applying a pushing force of approx.
500 kN (approx. 51 tons) on the idler
yoke, so be careful not to loosen the
mounting bolts suddenly. Loosen the
mounting bolts gradually until clearance
a between the flange of the recoil cylinder and idler yoke is 8 12 mm.
30-140
"
2 "
3) When the bolts are loosened, the torque will

suddenly drop. Check that the installed load
of the recoil spring is not applying any pushing force on the mounting bolts, then remove
all bolts.
If the torque increases (the installed load
of the recoil spring is applied) during the
loosening operation, stop the loosening
operation and disassemble as follows.
If the torque does not drop during steps
2) and 3) described above, and the
torque when the bolts are loosened remains large, there is probably damage to
recoil spring set bolts (10), or nut (11) at
the tip of the shaft has fallen off, so there
is danger that the idler yoke assembly
may fly off to the front. For this reason,
disassemble as follows.
When disconnecting the idler yoke assembly and recoil cylinder assembly, do
not stand in front of the idler yoke assembly or behind the recoil cylinder assembly until safety has been confirmed and
the recoil spring assembly has been removed.
D375A-5
i)
Prepare the following parts.

Bolt 1 (6) : 791-730-1110
Nut 2 (6) : 01580-12722
Washer 3 (6) : 01643-32780 (use
again)
Remove 6 bolts marked q, then install

bolts 1 , nuts 2 , and washers 3 .
Check that dimension L is less than
30 mm.
Screw in bolts 1 until they contact
the bottom of the yoke thread.
iii) Remove remaining 12 bolts (those not
marked q).
iv) Hold bolts 1 with a wrench to prevent
them from turning, and loosen 2 nuts 2
simultaneously on diagonally opposite
sides.
Be careful not to let the road bear on
only one bolt.
ii)

SPRING ASSEMBLY
v)
When recoil spring is fully extended and

torque has completely dropped in loosening direction of nut 2 , remove bolt 1 .
When clearance b is approx. 230
mm, the spring is fully extended.
10. Remove ring (12).
11. Pump in grease through lubricator (13), and remove cylinder (14) and piston assembly (15).
D375A-5
30-141
2 "
"

SPRING ASSEMBLY
12. Disassemble piston assembly (15) as follows.

1) Remove wear ring (16) from piston.
2) Remove snap ring (17), then remove packing (18).
13. Remove recoil spring assembly (19).

4
Recoil spring assembly : 550 kg
INSTALLATION

3 Cover mounting bolt:
277 32 Nm {28.25 3.25 kgm}
Before installing the pin, align the center of the

hole in the track frame and the dowel pin at the
recoil cylinder end with a bar.
Using a lever block, keep horizontal and be careful not to damage the oil seal at the track frame
end when installing.
Adjust the clearance. For details, see TESTING
AND ADJUSTING, Adjusting clearance of idler.
If the recoil spring set bolt is broken or the nut at
the tip of the shaft has fallen off, see ASSEMBLY
OF RECOIL SPRING ASSEMBLY when assembling.
2 Idler yoke assembly mounting bolt :
3 Idler yoke assembly mounting bolt :

1641.5 171.5 Nm {167.5 17.5 kgm}
To prevent air from accumulating inside the cylinder, fill with grease as follows.
1) Fill the inside of the cylinder with approx. 1.3
of grease.
2) Set with the cylinder drain hole facing up,
then loosen the lubricator.
3) Push the piston until it contacts the stopper.
This will push out the air and any extra
grease.
14. Remove holder (20) from recoil spring assembly.
30-142
"
2 "
D375A-5
DISASSEMBLY AND ASSEMBLY OF RECOIL

SPRING ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF RECOIL
SPRING ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.

model
cessity
Compressor
Cylinder
(686kN
{70ton})
790-101-1102
Pump
791-635-3160
Extension
791-685-8501
Part name
2 790-101-1600
2. Apply hydraulic pressure slowly to compress

spring, then remove lock plate (2) and remove
nut (3).
3. Release hydraulic pressure gradually and relieve
tension of spring.
DISASSEMBLY
1. Remove recoil spring assembly (1) with tool M2.
The spring is under high installed load, so be
careful to set it correctly.
Installed load of spring:
Approx. 500 kN {approx. 51 ton}
4. Remove rear pilot (5), spacer (6), bolt (7), and
front pilot (8) from spring (4).
D375A-5
30-143
2 "
"
ASSEMBLY
1. Assemble front pilot (8), bolt (7), spacer (6), and
rear pilot (5) to spring (4), then set in tool M2.
DISASSEMBLY AND ASSEMBLY OF RECOIL

SPRING ASSEMBLY
2. Apply hydraulic pressure slowly to compress

spring, and set so that installed length of spring
is specified value.
Installed length a of spring : 1,230.5 mm
Installed load of spring :
Approx. 500 kN {approx. 51 ton}
The spring is under high installed load, so be

careful to set all parts correctly.
3. Fit nut (3), then install lock plate (2).
Make clearance b of 0 - 10 mm between the
nut and lock plate to prevent the nut from
protruding from the end face of bolt (7).
Bring lock plate (2) and bolt (7) into tight contact, and secure in position.
2 Lock plate mounting bolt :
4. Gradually release hydraulic pressure to completely relieve tension of spring, then remove recoil spring assembly (1) from tool M2.
30-144
"
2 "
D375A-5
REMOVAL AND INSTALLATION TRACK

ROLLER ASSEMBLY
REMOVAL AND
INSTALLATION TRACK
ROLLER ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.

model
cessity
Lifting tool
790-401-1761
Adapter
790-401-1540
Shackle
790-401-1770
T-Bolt
791T-630-2320
Plate
Bolt
Washer
790-401-1700
12
Part name
13 01011-62700
01673-32780
4. Set steel plate 1 on track shoe, and operate

blade and ripper to lower chassis to a point
where track roller assembly contacts steel plate.
Run the engine at low idling and operate the
blade and ripper slowly.
"
REMOVAL
1. Loosen track shoe tension. For details, see REMOVAL OF TRACK SHOE ASSEMBLY.
2. Install tool L13 and secure bogie assembly (1).
q1
3. Operate blade and ripper, and jack up chassis to

a point where track roller assembly (2) comes up
from track shoe.
5. Remove mounting bolts, and leave track roller

assembly (2) on steel plate 1 .
6. Operate blade and ripper, and jack up chassis to
a point where track roller assembly (2) separates
from bogie.
D375A-5
30-145
2 "
"

ROLLER ASSEMBLY
7. Using a crane and bar, pull out track roller assembly (2) from steel plate to outside of body.
4
Track roller assembly:

150 kg (single flange)
160 kg (double flange)
INSTALLATION
q1
After removing tool L3, replace mounting bolts of

cover (3) with normal parts.
927 103 Nm {94.5 10.5 kgm}
Note that the installation location differs for

the single flange track roller assembly and
double flange track roller assembly.
S: Single flange
D: Double flange
Install the track roller assembly with the oil
filler plug on the outside.
30-146
"
2 "
D375A-5

ROLLER ASSEMBLY
After fitting the track shoe assembly temporarily, align the position of dowel pin (4).
3 Track roller assembly mounting bolt:
1,325 145 Nm {135 15 kgm}
When using assembly tool

Set tool L12 to bottom of track roller assembly,
then raise track roller assembly (2) and set to
track frame.
D375A-5
30-147
2 "
"

ROLLER ASSEMBLY

L13 Plate
30-148
"
2 "
D375A-5
DISASSEMBLY AND ASSEMBLY OF TRACK

ROLLER ASSEMBLY
Press-fitting force of seal guide:

36 - 63 kN {3.7 - 6.4 ton})
Press fit the seal guide so that press-fitting
dimension b from the end face of the shaft to
the top face of the seal guide is the dimension below.
Press-fitting dimension b: 77 0.2 mm
7. Using tool L11, charge with specified amount of

oil, then tighten oil filler plug.
5
Track roller: 1.4 - 1.5 (SAE140)
3 Oil filler plug:

206 49 Nm {21 5 kgm}
D375A-5
30-151
2 "
"
DISASSEMBLY AND ASSEMBLY OF TRACK

ROLLER ASSEMBLY

L8 Plate
L10 Push tool
30-152
"
2 "
D375A-5

BOGIE ASSEMBLY
3. Operate the blade and ripper to raise the machine body until the track roller is floated above
the track link.
Set a block between the track roller and track
link so that the machine body will not lower.
4. Set block 1 out of the track shoe according to
the height of the track link.
5. Set steel plate 2 on the track shoe and block 1 .
6. Operate the blade and ripper to lower the machine body until the track roller of the bogie assembly (1) comes in contact with steel plate 2 .
Operate the blade and ripper slowly with the
engine at low idling speed.
3) Remove floating seals (5) from the ends of

rings (4) and (7).
Keep the floating seals so that they will
not be damaged.

4) Set tool L15.
5) Pull out spacer (6) and rings (7) and (8).
Pulling out force:
205.8 - 382.2 kN {21 - 39 tons}
8. Remove the shaft and ring.

1) Set tool L14.
2) Push shaft (3) and ring (4) simultaneously to
the opposite side.
Pushing force:
137.2 - 274.4 kN {14 - 28 tons}
30-154
"
2 "
D375A-5

BOGIE ASSEMBLY
6) Remove spacer (6).

7) Remove spacer (9) and floating seal (10) between rings (7) and (8).
not be damaged.
8) Remove the shaft and rings from the bogie
on the opposite side according to steps 1) 7) above.
INSTALLATION
1. Assemble the pin assembly.
1) Using tool L18, install floating seals (5) to
rings (4) and (7) and install floating seal (10)
to the opposite side of ring (7) and ring (8).
When installing the floating seals, thoroughly degrease the O-rings and the Oring contact surfaces of the mating parts.
Check that the slant of each floating seal
is within 1mm.
9. Remove tool L13.

10. Place bogie assembly (1) on steel plate 2 .
11. Operate the blade and ripper to raise the machine body until the bogie assembly can be
pulled out.
Set a block between the track roller and track
link so that the machine body will not lower.
12. Sling bogie assembly (1) and slide it out on steel
plate 2 and remove it.
4
D375A-5
2)
3)
4)
5)
6)
Press fit shaft (3) to ring (8).

Install spacer (9).
Press fit ring (7) to shaft (3).
Install spacer (6).
2 Apply Anti-friction compound (LMP) to parts "a" (about 10 mm) of

rings (8) and (4).
Bogie assembly: 720 kg
30-155
2 "
"

BOGIE ASSEMBLY
2. Apply lever block 3 between the guard of bogie

assembly (1) and that of the bogie assembly on
the opposite side and slide bogie assembly (1)
on the steel plate to the mounting position.
2) Press fit pin assembly.

Insert the pin assembly with arrow "a" on
its end face up (in the mounting state on
the machine body).
Push in the pin assembly with cover (2).
Press fit the pin assembly to machined
surface "b" of the bogie.
2 Apply Anti-friction compound (LMP) to the all outside surface of the

pin.
Total press fitting force for pin assembly:
245 - 441 kN {25 - 45 tons}
3. Align the pin holes of the track frame and bogie

and set guide tool L17.

Using tool L19, supply the specified quantity of
oil.
Oil supply pressure: 0.49 MPa {5 kg/cm2}
5
Pin assembly: 95 - 115 cc (GO-140)
4. Press fit the pin assembly.

1) Set tool L16 and cover (2).
30-156
"
2 "
D375A-5

BOGIE ASSEMBLY
6. Press fit the pin assembly on the opposite side

according to steps 3 - 4 above.
7. Tighten the mounting bolts of pin assembly covers (2). (Install 2 covers, outside and inside
ones.)
927 103 Nm {94.5 10.5 kgm}
8. Adjust the track shoe tension. For details, see

TESTING AND ADJUSTING, Testing and adjusting track shoe tension.
D375A-5
30-157
2 "
"

BOGIE ASSEMBLY

L13 Plate
L17 Guide
30-158
"
2 "
D375A-5

BOGIE ASSEMBLY
ASSEMBLY
1. Assembly of pin assembly
Assemble the pin assembly according to the procedure in Installation of bogie assembly.
(Steps 3 - 5)

oil.
5
2. Set inner bogie (4) to outer bogie (5).

3. Press fitting of pin assembly
2) Press fit the pin assembly.
the machine body).
surface "b" of the bogie and secure level
difference "b" of 5 mm between the bogie and pin assembly.
2 Anti-friction compound (LM-P) to
the all outside surface of the pin.
245 - 441 kN {25 - 45 tons}

After press fitting the pin assembly, rock the
smaller bogie.
6. Tighten the mounting bolts of pin assembly covers (3).
(Install 2 covers, outside and inside ones.)
824 - 1,030 Nm {84 - 105 kgm}
7. Track roller assembly

Sling 2 track roller assemblies (2) and install
them to bogie assembly (1).
2 Track roller mounting bolt:
3 Track roller mounting bolt:

1,180 - 1,470 Nm {120 - 150 kgm}
30-160
"
2 "
D375A-5
7. Using tool L20, sling and hold 1st bogie (5).

9. Pull out the shaft and ring.

1) Set tool L14.
2) Push shaft (7) and ring (8) simultaneously to
the opposite side.
Pushing force:
137.3 - 274.6 kN {14 - 28 tons}
When the ring is pushed out, it interferes
with the idler. To prevent this, supply
grease to the track tension adjuster in
advance to push out the idler cushion assembly forward.
30-162
"
2 "
REMOVAL AND INSTALLATION OF 1ST

BOGIE ASSEMBLY
3) Remove floating seals (9) from the end faces

of rings (8) and (12).
not be damaged.
4) Set tool L15.
D375A-5

BOGIE ASSEMBLY
5) Pull out spacer (11) and rings (12) and (13).

Pulling out force:
205.8 - 382.2 kN {21 - 37 tons}
7) Remove spacer (14) and floating seal (10)
between rings (12) and (13).
not be damaged.
INSTALLATION
1. Assemble the pin assembly.
1) Using tool L18, install floating seals (9) to
rings (8) and (12) and install floating seal
(10) to the opposite side of ring (12) and ring
(13).
When installing the floating seals, thoroughly degrease the O-rings and the Oring contact surfaces of the mating parts.
Check that the slant of each floating seal
is within 1mm.
10. Lower bogie (5) on the steel plate and pull it out.
4
Bogie assembly: 110 kg

2)
3)
4)
5)
6)
D375A-5
Press fit shaft (7) to ring (13).

Install spacer (14).
Install spacer (11).
2 Apply Anti-friction compound

(LM-P) to parts "a" (about 10 mm)
of rings (13) and (8).
30-163
2 "
"

BOGIE ASSEMBLY
2. Place bogie assembly (5) on steel plate 1 and

slide it to the center.
3. Using tool L20, set the bogie in position.
2) Press fit pin assembly .

the machine body).
surface "b" of the bogie and secure level
difference "b" of 5 mm between the bogie and pin assembly.
2 Apply Anti-friction compound
(LM-P) to the all outside surface of
the pin.
245 - 441 kN {25 - 45 tons}
4. Align the pin holes of the track frame and bogie

and set guide tool L17.

oil.
5. Press fit the pin assembly.
30-164
"
2 "
D375A-5

BOGIE ASSEMBLY

8. Install covers (6).
(Install 2 covers, outside and inside ones.)
9. Install eyebolts to the pad mounting bolts (M12 x
2 pieces) of bogie (5) and pull up and hold the
bogie.
13. Adjust the track shoe tension. For details, see

testing and adjusting, TESTING AND ADJUSTING TRACK SHOE TENSION.
10. Using tool L21, insert the shaft in track roller assembly (4), then sling and set it on the track
shoe, balancing it.
4
Track roller assembly: 150 kg
11. Lower the machine body slowly. When the clearance between bogie (5) and shaft (3) becomes
about 20 mm, install cap (15) and secure it with
bolt (2) temporarily.
12. Align the dowel pin hole and tighten bolt (2) securely.
2 Cap mounting bolt:
3 Cap mounting bolt:
1,180 - 1,470 Nm {120 - 150 kgm}
D375A-5
30-165
2 "
"

BOGIE ASSEMBLY

L17 Guide
L21 Tube
30-166
!
2 !
4
D375A-5

BOGIE ASSEMBLY
L21 Plate
D375A-5
30-166-1
4
EXPANDING AND ASSEMBLY

TRACK SHOE INSTALLATION

CHECK BEFORE EXPANDING TRACK
SHOE ASSEMBLY
Since it may be very dangerous to expand the
track shoe assembly, check the following items in
advance.
Do not loosen the lubricator more than 1 turn.
Loosen lubricator (1) of the adjustment cylinder to discharge the grease and move the
machine in reverse a little and check that the
track shoe is loosened.
After the shoe is loosened, perform EXPANDING TRACK SHOE ASSEMBLY
(NORMAL).
If the track shoe is not loosened by the above
work, the track frame may have an internal
trouble (damage of the recoil spring or recoil
spring set bolt, fall of the shaft end nut, etc.)
If the track shoe is not loosened, perform
EXPANDING TRACK SHOE ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL TROUBLE).
D375A-5
1. Sling the end of the master link and move the

machine slowly in reverse to expand track shoe
assembly (4).
Length of track shoe: Approx. 12.5 m
30-167
2 "
"

EXPANDING TRACK SHOE ASSEMBLY
EXPANDING TRACK SHOE ASSEMBLY
(When track frame has internal trouble).

If any abnormality is detected by CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY,
perform the following procedure.
If the track shoe is removed while the track frame
has an internal trouble, it may spring back. Even
if the track shoe is removed, the idler may jump
out, and that can cause a serious result. Accordingly, expand the track shoe according to the following procedure.
(Normal)
If any abnormality is not detected by CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY,
perform the following procedure.
1. Remove the work equipment. For details, see

REMOVAL OF WORK EQUIPMENT ASSEMBLY.
1. Set the master link in position.

Set the master link above the idler (a little after the idler center).
Set a block (1) and (2) between the front side
of the idler and carrier roller so that the mating part of the master link will not open until
the master bolt is pulled out.
2. Loosen lubricator (1) and move the machine forward and in reverse to discharge the grease.
Do not loosen lubricator (1) more than 1 turn.
Check that the all grease has been discharged.
2. Loosen the track shoe.

Do not loosen lubricator (1) more than 1 turn.
Loosen all of them by 1 - 2 turns first until
they are turned lightly, then pull them out. Do
not loosen and pull out the bolts 1 by 1.
If the bolts are turned forcibly before they become light, the threads of them and master
link may be damaged.
30-168
"
2 "
D375A-5

3. Move the machine slowly forward against large

block 1 or a wall (or the blade of another machine of the similar size of the machine to be repaired, if available) to press the track shoe on the
idler side. When the recoil spring is distorted,
stop and apply the brake.
At this time, set the master link between the idler
and front carrier roller.
For safe work, apply a lever block between the
carrier roller support and link.
4. Remove track shoe (5) and disconnect master
link (6).
5. Move the machine slowly in reverse to expand
track shoe assembly.
INSTALLATION OF TRACK SHOE

ASSEMBLY
Carry out installation in the reverse order to EXPANDING.
q1
Adjust the track shoe tension. For details,

see testing and adjusting, TESTING AND
ADJUSTING TRACK SHOE TENSION.
Tighten the all 4 bolts with fingers until the
master link mating faces are fitted.
If the bolts are tightened forcibly before the
master link mating faces are fitted, the
threads of the bolts and master link may be
damaged.
q2
Tighten the shoe mounting bolts for the master link in the following order.
2 Shoe mounting bolt:

Anti-seizure agent (Maruzen
MOLYMAX No. 2 or equivalent)
3 Shoe mounting bolt:
1st time:
686 68.6 Nm {70 7 kgm}
2nd time:
Retighten by 180 10
D375A-5
30-169
2 !
WHOLE DISASSEMBLY AND

ASSEMBLY OF TRACK SHOE
WHOLE DISASSEMBLY
When disassembling the track shoe, see "Parts
judgment guide, Undercarriage, Lubricated
track" and "Parts judgment guide, Undercarriage, Reversing procedure for pin bushing".
1. Removal of shoe
Sling the shoe assembly and set it with the shoe
up on the floor and remove the shoe by using a
shoe bolt impact wrench.
If a shoe bolt is not loosened after it is unscrewed by 1 turn (If its torque is not reduced
to 0), loosen the other bolts first, and it will be
removed smoothly.
If a shoe bolt is turned forcibly while its
torque is not 0, it and link will adhere to each
other and they will need to be repaired.
When moving the shoe assembly, take care
not to damage the master link.
If it is obliged to cut a shoe nut with gas, keep
the seal temperature below 80C to prevent
thermal deterioration of the seal and take
measures to prevent the spatters from entering through the clearances among the links.
2) Operate the left cylinder to pull out the pin

and bushing from the left link simultaneously.
Check the pulling out force of the pin and
bushing which will be reversed and assembled again, then pull out them simultaneously.
The wedge link is broken with a bang.
This sound does not indicate abnormality.
2. Disassembly of link
1) Set the link assembly on a link press and hit
it with a hammer so that the bushing will be
fitted to the jaw.
If the link tread, outside of the bushing,
etc. are worn, adjust the height of the jaw
or guide plate and align the pin and
bushing with the disassembly jig so that
the link hole will not be damaged during
disassembly work.
If the pin and bushing are not aligned
well, the link hole may be damaged and
the pin and bushing may be broken during disassembly work.
Using tool R1, drive the small plug of the
pin inward after the disassembly work so
that the workplace will not become dirty.
D375A-5
30-171
2 "
"
3) Return the left cylinder and operate the right

cylinder to pull out the pin and bushing from
the right link simultaneously.

2) Measure the outside diameter of the press

fitting parts of the pin and bushing and the inside diameter of the pin and bushing fitting
parts of the link with a micrometer and a cylinder gauge to see if the allowable fitting allowance is obtained. When using the pin,
bushing, and link for a lubricated track, however, secure the standard fitting allowance
between the pin and link.
If the allowable fitting allowance is not
obtained, replace the parts with new
one.
For the dimensional criteria, see MAINTENANCE STANDARD.
4) Return the right cylinder and take out the

links, pins, bushings, and spacers on both
sides and feed the next 1 set of the link assembly to the jaw.
If the bushing ends and sealing surfaces
are damaged, oil will leak. Accordingly,
handle them carefully.
Since the broken wedge link has sharp
edges, take care not to cut your hands
with them.
3. Inspection
Check the parts for the following items to see if
they can be used for a lubricated track or a
grease-filled track, then examine them generally
and determine to use them for a lubricated track
or grease-filled track.
For judgment of reuse of the parts, see
"Parts judgment guide, Undercarriage, Lubricated track".
1) Check the parts visually for damage. If a
part seems to be damaged, check it by dye
penetrant test or magnaflux inspection. If it
has any crack, it cannot be used again. Discard it.
30-172
"
2 "
D375A-5
Precautions for storage

1) Store the seal without removing it from the
link so that the counterbore portion will not
be rusted and take care not to damage the
seal lip.
2) Apply rust-preventive oil to the pin and bushing fitting parts, shoe mating surface, and
master link mating surface of the link.
3) When storing, apply rust-preventive oil to the
all surfaces of the pin, bushing, and spacer.
Take care not to damage the ends of the
bushing in particular.

2) When reusing the pin, chamfer its end corners smoothly with a grinder. Remove the
nodules sticking to the press fitting parts with
the grinder, too.
If the ends are worn and sharpened, they
may scuff the press fitting parts and
cause oil leakage.
3) If the link, pin, bushing, and spacer are dirty,
clean them. Remove the nodules sticking to
the link and bushing with the grinder, too.
Since these parts rust easily, clean them
just before assembling them.
Do not polish the bushing ends. If they
are polished, oil may leak.
WHOLE ASSEMBLY
For the whole assembly of the track shoe, see
"Parts judgment guide, Undercarriage, Reversing procedure for pin bushing".
1. WHEN RECYCLING FOR LUBRICATED

TRACK
1. Preparation work
1) Cleaning seal assembly
Remove the seal assembly from the link and
divide it into the seal ling and load ring, then
clean them.
Since the seal ring and load ring are deteriorated easily by the cleaning liquid
(trichloroethylene etc.), clean them
quickly. After cleaning them, wipe off the
cleaning agent from them.
D375A-5
30-173
2 "
"
4) If the large plug was pulled out, drive it in by

using tool R3.
In this case, clean the pin hole in advance by
using tool R2.
i) Insert the plug through the plug insertion
window into the guide hole.
ii) Push the bar with the hand until the plug
stops.
iii) Push the plug with the bar to press the
guide against the pin.
iv) Drive in the bar with a hammer.
Driving distance "a" from pin end:
11 2 mm
If the chamfered part of the pin hole
has been worn, chamfer it with a
small-sized grinder (grindstone tip
angle: 45- 60) so that the plug will
not be damaged.
Coat the plug with GO90 and drive it
with the small diameter end ahead.
30-174
"
2 "

5) Installation of seal assembly

Clean the counterbore portion of the link
carefully and push in the seal to the bottom
by using tool R6.
If oil is sticking to the counterbore portion
of the link or seal assembly, the seal will
turn and its sealing performance will lower. Accordingly, do not apply any oil.
When inserting the seal in the counterbore portion, take care that oil not stick to
the seal and counterbore portion.
D375A-5
6) Adjust the dimensions of the press fitting jig

of the link press to keep the projection of the
pin and bushing constant and keep the installed dimensions of the seal within the
standard range.
For the standard dimensions, see DIMENSIONS TABLE OF FITTING JIG OF
LINK.
If the pin end (part P) or link sides (parts
Q and R) are worn, add the dimensions
of the worn parts when adjusting the
standard dimensions so that the projections of the pins and bushings on both
sides will be even.

7) Adjust the relief pressure of the link press so

that the pressing force of the press will not
exceed the standard value.
If the pressing force is too strong, the
spacer will be pressed forcibly against
the bushing. As a result, the spacer may
be broken and it and bushing may be
worn abnormally.
Pushing force of pin and bushing: 980 kN
{170 tons}
Pushing force = 1.8 x Average pressure
(Adjust the relief pressure of the link
press to set the pushing force.)
2. Assembly of link
1) Apply oil (GO90) to the mating surfaces of
the pin and bushing with a clean brush and
assemble them, then set them before the jaw
of the link press.
When reusing (reversing) the bushing,
set the worn outside surface of the bushing on the shoe fitting side of the link (set
the bushing with the worn outside surface up on the link press).
D375A-5
30-175
2 "
"
2) Press fit the master links on both bushing

sides to the bushing with the shoe fitting faces up.
At this time, use the master links on the
pin side as supports.
Press fitting force for bushing:
196 - 343 kN {20 - 35 tons}
4) Turn over the master links and check that

they are press fitted in parallel.
5) Measure the projections of the bushing on
both sides with a depth gauge.
Adjust the press fitting jig of the link
press so that the projections on both
sides will be even.
3) Using the shoe bolt hole pitch gauge, press

fit the master links until the distance between
the shoe bolt holes of both links is the standard value.
Remove the all steel chips caused by
press fitting of the bushing with compressed air.
6) Send the master links and set the next pin

and bushing.
When reusing a pin, install it so that its
side hole will be the link tread side similarly to a new one. If it is not installed so,
its strength may be lowered. Accordingly, indicate the direction of the side hole
on the end face to prevent a mistake.
30-176
"

2 "
D375A-5
7) Apply gasket sealant (198-32-19890) to the

pin fitting hole of the links to prevent oil from
oozing out of the scuffed parts of the pin fitting parts.

9) Set the right jig on the receiving side and the

left one on the pushing side and press fit the
pin and bushing simultaneously.
If the pin and bushing have play when
they are press fitted, the seal may come
off the link. To prevent this, press fit
smoothly. If the seal comes off the link,
stop press fitting and set the seal to the
link correctly, then star t press fitting
again.
Press fitting force for pin and bushing:
392 - 686 kN {40 - 70 tons}
8) Set the right link and install the spacer to the

pin.
Check that the seal surface and bushing
end are free from dir t and apply oil
(GO90) to them with a clean cloth or
brush.
When installing the spacer, wipe it with a
clean cloth.
10) Using the spacer for fine adjustment, press
fit the pin and bushing until the pin end is fitted to the bottom of the receiving jig.
Adjust the depth of the receiving jig hole
so that the projections of the pin on both
sides will be even.
D375A-5
30-177
2 "
"
11) Set the left link and install the spacer to the
pin.
Apply oil similarly to the right link.

13) Press fit until the link, spacer, and bushing

are fitted together.
Actually, you cannot see from outside if
the above parts are fitted.
Accordingly, control the hydraulic pressure of the link press. Set the relief pressure to a proper level and heighten the
hydraulic pressure to that level.
For setting of the relief pressure, see
PREPARATION WORK.
Check that adjacent 2 links can turn
around each other.
12) Set the left jig on the receiving side and the
right one on the pushing side and press fit
the left link.
When press fitting, take care that both
seals and spacers will not come off.
Press fitting force for link:
392 - 686 kN {40 - 70 tons}
14) Using a shoe bolt hole pitch gauge, measure
the distance between the shoe bolt holes
and check that the result is within the standard range.
If the distance between the shoe bolt
holes is longer than the standard range,
disassemble and check for abnormality,
then press fit again.
If the distance between the shoe bolt
holes is shorter than the standard range
and the shoe cannot be installed, the
spacer or bushing end may be worn
more than the allowable limit. In this
case, disassemble and replace the
parts.
30-178
"
2 "
D375A-5
15) Install the ring to jig R8.

18) Using jig R10, push in the ring.

Pushing force for ring:
294 - 372 kN {30 - 38 tons}
16) Match the jig to the pin hole and push it in until the ring is inserted in the pin groove.
A sound is made when the ring is inserted in the pin groove.
19) After each link is assembled, bleed air from

the pin by using tool R4 and check the sealing performance.
Keep the degree of vacuum inside the
pin at 86.7 - 93.3 kPa {650 - 700 mmHg}
for 5 seconds and check that the pressure does not change.
If the pressure changes, disassemble
and check the seal. If the seal is free
from abnormality, assemble again.
17) Using jig R9, insert the ring in the pin groove
on the opposite side similarly.
D375A-5
30-179
2 "
"
20) Using tool R4, supply oil (G090) until the oil
supply pressure rises to 196.1 - 294.2 kPa {2
- 3 kg/cm2}.
In a cold or very cold district, supply Komatsu genuine oil (150-09-19270 or 19532-61990) having better low-temperature characteristics instead of G090.
If the oil pressure is heightened too
much, it has bad effects on the seal.
Take care.
Supply oil so that depth L of the hollow of
the pin hole will be in the following range
when the link is left with the small plug
side up (when the link assembly is
placed on its side) for 30 minutes.
Dimension L: 40 - 70 mm
30-180
"
2 "

21) After supplying oil, drive in the small plug to

the specified position, using tool R4.
Apply G090 around the small plug.
Drive in the plug to the following depth.
Driving depth from end face: 7.5 1 mm
22) Assemble the master link on the pin side at

last.
Check that the master links on both sides
are press fitted in parallel.
D375A-5
3. Installation of shoe
1) Set the link assembly on the bed and install
the shoe with a shoe bolt impact wrench and
a torque wrench.
3 Shoe bolt (Regular link)
Initial torque:
1,372 137.2 Nm {140 14 kgm}
Retightening angle: 120 10
2 Shoe bolt:

2) When installing a double track, place the assembled double shoes on a level place in 1
line with the shoe side up. Pull pin-side master link (1) and bushing-side master link (2)
together and set them to each other by the
mating faces. Place shoe (3) on the links
and check that shoe bolt (4) can be tightened
easily until the mating faces of the links are
fitted together, then connect the links with
the master bolts.
2 Shoe bolt:
3 Shoe bolt (Master link)

Initial torque:
686 68.6 Nm {70 7 kgm}
Tighten the bolts in the order of 1 - 4 .
D375A-5
30-181
2 "
"
2. WHEN RECYCLING FOR GREASEFILLED TRACK

1. Preparation work
1) Cleaning seal assembly
Remove the seal assembly from the link
and divide it into the seal ling and load
ring, then clean them.
Since the seal ring and load ring are
deteriorated easily by the cleaning
liquid, clean them quickly. After
cleaning them, wipe off the cleaning
agent from them.

3) Drive in the large and small plugs by using

tools R3 and R5.
i) Insert each plug through the plug insertion window into the guide hole (Apply oil
to the plug).
ii) Push the bar with the hand until the plug
stops.
iii) Push the plug with the bar to press the
guide against the pin.
iv) Drive in the bar with a hammer.
Driving distance "a" from pin end:
Small plug: 7.5 1 mm
Large plug: 11 2 mm
If the plugs were not pulled out when
the shoe was disassembled, reuse
them as they are.
2) When reusing the pin, chamfer its end corners carefully with a grinder so that it will be
press fitted smoothly.
30-182
"
2 "
D375A-5
4) If the outside of the pin, surfaces of the spacer, and ends and inside of the bushing are
dirty, clean them.
5) Apply grease to the outside of the pin and
surfaces of the spacer.
6) Installation of seal assembly
Clean the counterbore portion of the link
carefully and push in the seal to the bottom by using tool R6.
If grease is sticking to the counterbore portion of the link or seal assembly, the seal will turn and its
sealing performance will lower. Accordingly, do not apply any oil.
7) Adjust the dimensions of the press fitting jig

of the link press to keep the projection of the
pin and bushing constant and keep the installed dimensions of the seal within the
standard range.
For the standard dimensions, see DIMENSIONS TABLE OF FITTING JIG OF
LINK PRESS.
If the pin end (part P) or link sides (parts
Q and R) are worn, add the dimensions
of the worn parts when adjusting the
standard dimensions so that the projections of the pins and bushings on both
sides will be even.
D375A-5

2. Assembly of link
1) Apply lithium grease (G2-LI) to the mating
surfaces of the pin and bushing and assemble them, then set them before the jaw of the
link press.
When reusing (reversing) the bushing,
set the worn outside surface of the bushing on the shoe fitting side of the link (set
the bushing with the worn outside surface up on the link press).
2) Press fit the master links on both bushing

sides to the bushing with the shoe fitting faces up.
At this time, use the master links on the
pin side as supports.
Press fitting force for bushing:
196 - 343 kN {20 - 35 tons}
30-183
2 "
"
3) Using the shoe bolt hole pitch gauge, press

fit the master links until the distance between
the shoe bolt holes of both links is the standard value.
Remove the all steel chips caused by
press fitting of the bushing with compressed air.
4) Turn over the master links and check that
they are press fitted in parallel.
5) Measure the amount of protrusion of the left

and right bushing with a depth gauge.
Adjust the press fitting jig of the link
press so that the projections on both
sides will be even.

If the outside of the pin is worn, install it

so that the un-worn surface will be on the
traction side. In this case, install the pin
so that its side hole will be the link tread
side, too.
7) Set both links and operate both pushing jigs

to press fit the pin and bushing simultaneously.
If the pin and bushing have play when
they are press fitted, the seal may come
off the link. To prevent this, press fit
smoothly. If the seal comes off the link,
stop press fitting and set the seal to the
link correctly, then star t press fitting
again.
Pushing force of pin and bushing: 980 kN
{100 tons}
Pushing force 1.8 x Average pressure
(Adjust the relief pressure of the link
press to set the pushing force.)
6) Send the master links and set the next pin

and bushing.
When reusing a pin, install it so that its
side hole will be the link tread side similarly to a new one. If it is not installed so,
its strength may be lowered. Accordingly, indicate the direction of the side hole
on the end face to prevent a mistake.
30-184
"
2 "
D375A-5
8) Using a shoe bolt hole pitch gauge, measure

the distance between the shoe bolt holes.
When the distance is in the standard range,
stop press fitting.
9) Install the ring to jig R8.

11) Using jig R10, push in the ring.

Pushing force for ring:
294 - 372 kN {30 - 38 tons}
12) Assemble the master link on the pin side at

last.
Check that the master links on both sides
are press fitted in parallel.
3. Shoe (regular link portion)
Set the link assembly on the bed and install the
shoe with a shoe bolt impact wrench and a
torque wrench.
2 Shoe bolt :
Lubricant containing molybdenum
disulfide (LM-P)
10) Match the jig to the pin hole and push it in until the ring is inserted in the pin groove.
Using jig R9, install the ring on the opposite
side similarly.
A sound is made when the ring is inserted in the pin groove.
D375A-5
3 Shoe bolt (Regular link):

1,372 137.2 Nm
Initial torque:
{140 14 kgm}
120 10
Retightening angle:
30-185
2 "
"

4. Assembly of 1/2 track

Place the assembled 2 shoes on a level place in
1 line with the shoe side up. Pull pin-side master
link (1) and bushing-side master link (2) together
and set them to each other by the mating faces.
Place shoe (3) on the links and check that shoe
bolt (4) can be tightened easily until the mating
faces of the links are fitted together, then connect the links with the master bolts.
2 Shoe bolt:
Lubricant containing molybdenum
disulfide (LM-P)

Initial torque:
686 68.6 Nm {70 7 kgm}
Tighten the bolts in the order of 1 - 4 .
30-186
"
2 "
D375A-5
DIMENSIONS TABLE OF FITTING

JIG OF LINK PRESS
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS
Unit: mm
Dimensions of jig
a
4.2
2.0
52.1
Precaution
The link receiving faces of the jaw (1) must be vertical.
Replaceable wear plate (2) type shown below is desirable.
D375A-5
30-187
2 "
"

1 LINK IN THE FIELD
DISASSEMBLY AND
ASSEMBLY OF
1 LINK IN THE FIELD
SPECIAL TOOLS
Symbol
Part No.
Symbol
Part No.
Part name

model
cessity
791-646-7351
Push tool
21 791-680-5551
Guide
791-660-7460
Pin Brush
22 791-680-9630
Adapter
791-646-7900
Push tool
(L burash)
23 791-632-1160
Guide
24 195-32-61210
Bolt
791-701-3000
Seal
checker
791-601-1000
Oil pump
791-932-1110
791-632-1021
Push tool
(S burash)
Installer
1 791-632-1100
Remover
and installer
assembly
2 791-632-1130
Adapter
3 790-434-1610
Guide
4 01010-51440
Bolt
5 791-685-9510
Frame
6 791-685-9530
Rod
7 791-685-9520
Frame
8 791-685-9550
Nut
9 04530-12030
7 10 791-685-9560
Eye bolt
Bolt
11 791-126-0150
Adapter
12 791-685-9540
Rod
13 791-632-1140
Adapter
14 791-680-5520
Guide
15 01010-51030
Bolt
16 791-632-1150
Pusher
17 791-685-9620
Extention
18 791-632-1180
Adapter
19 791-680-5543
Adapter
20 791-632-1170
Guide
30-188
"

model
cessity
Part name
2 "
Cylinder
(1,470kN
{150ton})
26 790-101-1102
Pump
27 790-101-4200
Cylinder
(294kN
{30ton})
28 791-680-1630
Spacer
R 7 25 790-101-4300
"
DISASSEMBLY
1. Install tool R7-2 to link (1) with tool R7-24 and install tool R7-3 with tool R7-4.
Use the shoe bolts for tool R7-24.
D375A-5

1 LINK IN THE FIELD
2. Assemble tools R7-25 and R7-5 - R7-11, then

sling and set them on the shoe.
If the cylinder reaches the stroke end, connect tool R7-17 and repeat the work.
3. Insert tool R7-12 from the cylinder side and install it with 2 tools R7-8.
5. Set tools R7-27 and R7-28 to the center on the

roller tread side of the link to be disassembled
and connect tool R7-26. Apply hydraulic pressure to open the link by 5 - 6 mm and disconnect
it.
4. Set tools R7-13 - R7-16 and connect them by

tool R7-26. Apply hydraulic pressure and pull
out pin (2).
6. Repeat steps 1 - 4 to pull out pin (3) on the opposite side.
D375A-5
30-189
2 "
"
7. Repeat step 5 to remove link (4).

1 LINK IN THE FIELD
2) Set tool R7-19 to the pin-side end of the link

and press fit pin (7).
Set the pin with its side hole on the link
tread side.
Press fitting force of pin:
206 - 323 kN {21 - 33 tons}
ASSEMBLY
1. Assemble the link sub-assembly according to
the following procedure.
1) Set tool R7-18 to the bushing-side end of link
(5) and press fit bushing (6).
Press fitting force of bushing:
196 - 294 kN {20 - 35 tons}
2. Set link sub-assembly (8) to the link to be connected.
3. Set link (9) on the opposite side and support it

with tool R7-20.
30-190
"
2 "
D375A-5
4. Similarly to the disassembly procedure, set tools

R7-25, R7-5 - R7-12, and R7-17 to the link.
5. Use R7-19 and R7-21 to press fit the pin. Use
tools R7-22, R7-18, and R7-21 to press fit the
bushing. Press fit the pin and bushing alternately.
Press fit the pin first. After the bushing is engaged with the link, remove tool R7-20 installed in step 3, then press fit the bushing.
206 - 323 kN {21 - 33 tons}
Press fitting force of bushing:
196 - 294 kN {20 - 30 tons}

1 LINK IN THE FIELD
7. Set link (11) to be connected to link (10) and connect them with tool R7-23, then remove tools R727 and R7-28.
8. Similarly to the disassembly procedure, set tools

R7-2 - R7-12 and press fit pin (12) to the link.
2 Pin fitting hole of link:
Gasket sealant (198-32-19890)
6. Similarly to the disassembly procedure, push

open link (10) to be connected by using tools R727 and R7-28.
D375A-5
Set the pin with its side hole on the link tread
side.
412 - 646 kN {42 - 66 tons}
If the cylinder reaches the stroke end, insert
tools R7-17 and R7-14 - R7-16 and repeat
the work.
30-191
2 "
"
DISASSEMBLY
For the method of using tool R7, see DISASSEMBLY OF 1 LINK IN THE FIELD.
1. Removal of track shoe assembly
Remove the track shoe assembly from the track
frame. For details, see EXPANDING TRACK
SHOE ASSEMBLY.
2. Disassembly of shoe
Disconnect the all master links and divide the
shoes into 4 parts.
3. Removal of master link
Master pin type
1) Cutting of regular link with gas
Cut the parts marked
with gas and remove the parts marked
.
Necessary special tool: Gas cutting machine
2) Removal of regular link

Push pin (1) in the direction of with a press
to remove it from link (2), then pull pin (1) and
link (3) together out of bushing (4).
D375A-5
DISASSEMBLY AND ASSEMBLY OF MASTER LINK
Master link type

1) Cutting and removal of master link on bushing side with gas
. Move master
links (5) and (6) in the direction of and to
pull them out. Then, push pins (8) and (9)
out of regular link (7) in the directions of
and with a press.
Necessary special tools:
1. Gas cutting machine
2. Tool R7
2) Removal of master link on pin side

. Push pin (10)
out of link (11) in the direction of
with a
press. Then, pull pin (10) and link (12) together out of bushing (13).
Necessary special tools:
1. Gas cutting machine
2. Tool R7
30-193
2 "
"
ASSEMBLY
For the method of using tool R7, see DISASSEMBLY of 1 link in the field.
2. Installation of link at bushing end

1) Expand the center of the link tread with tool
R7 as shown in the figure. (Expand the link
end by 10 mm.)
1. Assembly of link at bushing end

1) Press fit bushing-side master link (1) at
bushing end to bushing (2) with a press.
When press fitting both master links,
take care that they will be in parallel with
each other.
Do not damage the mating surfaces of
the master links and end faces of the
bushing.
Unit: mm
L1
184 0.7
L2
253.4 0.7
D1
Drill 33 in diameter
D2
30 2.0
2) Set spacer (3) and seal assembly (4) to the

counterbore of the link of the connecting
part.
3) Match the pin hole and bushing hole to each

other and connect the pin and bushing with
guide pin 1 .
30-194
"
2 "
D375A-5
4) Press fit pin (5) with tool R7 and install at

bushing end master link (1).
2 Apply gasket sealant (198-3219890) to the pin hole of the link.
Set the pin with its side hole on the link

tread side.
5) Using tools R7, R8, R9, and R10, install the
ring.
6) Install the shoe to the link of the connecting

part.
7) Drive large plug (6) with tool R3 and supply
oil with tool R4, then drive small plug (7) with
tool R5.
Adjust the end play of the connecting

part (the thrust play between the links
before and after the pin) to 0 - 0.13 mm.
Take care that dirt and sand will not stick
to the seal, spacer, end of bushing, and
tap-hole mating face of the master link.
3. Assembly of at pin end link
1) Set spacer (3) and seal assembly (4) to the
counterbore of the master link.
2) Pass pin (9) through bushing (8) and set and

press fit pin-side master links (10) at pin end
from both sides with tool R7.
3) Using tools R7, R8, R9, and R10, install the
ring.
4) Drive large plug (11) with tool R3 and supply
oil with tool R4, then drive small plug (12)
with tool R5.
When press fitting both master links,

take care that they will be in parallel with
each other (Bushing side and pin side).
Do not damage the mating surfaces of
the master links and end faces of the
bushing.
D375A-5
30-195
2 "
"
4. Connection of master links

Place the assembled 2 shoes on a level place in
1 line with the shoe side up. Pull master link (13)
at pin end and bushing-side master link (14) together and set them to each other by the mating
faces. Place the shoe on the links and check that
the shoe bolt can be tightened easily until the
mating faces of the links are fitted together, then
connect the links with the master bolts.
Initial torque:
686 68.6 Nm {70 7 kgm}
30-196
"
2 "
D375A-5

PIVOT SHAFT ASSEMBLY
REMOVAL AND
INSTALLATION OF
SPECIAL TOOLS
Symbol
Part No.
Part name

model
cessity
1 791T-650-2330
Sleeve
"
2 791T-650-2340
Plate
"
3 790-201-3310
Bolt
4 790-101-2510
Block
5 790-101-2570
Washer
6 01580-01613
Nut
7 01643-31645
Washer
8 790-105-2300
Jack
assembly
9 790-101-1102
Pump
REMOVAL
INSTALLATION
1. Track frame assembly

Remove the track frame assembly. For details, see REMOVAL OF TRACK FRAME
ASSEMBLY.
2. Sling pivot shaft assembly (1) temporarily and

remove the mounting bolts. Using forcing screw
q1
1 , pull out the pivot shaft assembly.
4
q2
3. Remove seal (2) and cover (3).
Pivot shaft assembly: 390 kg
q1
2 Press fitting face of pivot shaft:

q2
Using tool P, press fit seal (2) to the pivot

shaft.
2 Press fitting face of seal:
Check that press fitting dimension "a" of the

seal from the shaft end is in the standard
range.
Press fitting dimension "a":
655 1.0 mm
D375A-5
30-197
2 "
"


P1 Sleeve
P2 Plate
30-198
"
2 "
D375A-5

EQUALIZER BAR
REMOVAL AND
INSTALLATION OF
EQUALIZER BAR
SPECIAL TOOLS
Symbol
Part No.
Part name

model
cessity
!
791-650-1300
Remover
791-735-1123
Sleeve
790-434-1050
Screw
01580-02419
Nut
01643-32460
Washer
790-101-2102
Puller
(294kN
{ton})
790-101-1102
Pump
3. Remove seal (2) and washer (3) together. q 1

Perform this procedure for only the right track
frame.
4. Remove washer (4) and spacer (5).
Receive the oil flowing out of the pivot case
6
Pivot case: 18
5. Set hydraulic jack 1 (490 kN (50 tons}) under

the radiator guard.
REMOVAL
1. Remove the engine underguard and power train
underguard (front).
4
Engine underguard: 290 kg

Power train underguard (front): 280 kg

For the right track frame, disconnect the 4
hoses for the blade tilt cylinder.
Since the whole machine body will be raised
by using the blade, plug the hoses on the tilt
cylinder side securely.
D375A-5

7. Remove cover (7) and loosen bolt (8).
30-199
2 "
"
8. Loosen clamping bolt (9) of the rear equalizer

bar side pin.
q2
q3
9. Remove side pin (10).
If the equalizer bar hole is not aligned with
the track frame hole, the pin cannot be pulled
out easily. Accordingly, adjust the height of
the equalizer bar with hydraulic jack 1 .

EQUALIZER BAR
12. Disconnect lubrication tube (12).

13. Remove 2 lock plates (13).
q4
14. Using tool N1, remove center pin (14).

q5
If the equalizer bar hole is not aligned with
the main frame hole, the pin cannot be pulled
out easily. Accordingly, adjust the height of
the main frame with hydraulic jack 1 .
10. Repeat steps 6 - 9 and remove the side pin on

the opposite side.
11. Operate hydraulic jack 1 slowly to lower the machine body until the equalizer bar touches both
track frames.
30-200
"
2 "
D375A-5

EQUALIZER BAR
15. Operate the blade to raise the front part of the

machine body and set stand 3 under the radiator guard.
INSTALLATION
q1
After removing the grease from the pressfitting surface of the seal, coat with gasket
sealant (LG-6).
Be careful not to install with the seal displaced in the direction of twisting.
q2
2 Inside surface of bushing :

Grease (G2-LI)
16. Sling equalizer bar (15) and remove it over the

main frame and track frame.
After removing the equalizer bar, do not lower the machine body.
4
Before installing the pin, operate hydraulic

jack 1 to adjust the height of the main frame
and align the center of the equalizer bar hole
and track frame hole.
Set the pin with the grease hole facing the
outside of the machine.
q3
Fit pin and bushing, install cover, then install

the cover and cushion.
Tighten bolt (8), then tighten cover mounting
bolt.
Equalizer bar assembly: 500 kg
q4
3 Lock plate mounting bolt :

549 59 Nm {56 6 kgm}
q5
2 Equalizer bar bushing and main frame

Grease (G2-LI)
bushing :
Before installing the pin, operate the crane to
align the center of the main frame hole and
the equalizer bar hole.
Refilling with oil (pivot case)

D375A-5
Pivot case : 18 (SAE30)
30-201
2 "
"
DISASSEMBLY AND ASSEMBLY OF EQUALIZER

BAR BUSHING
DISASSEMBLY AND
ASSEMBLY OF EQUALIZER
BAR BUSHING
SPECIAL TOOLS
Symbol
Part No.

model
cessity
Bracket
"
2 791T-650-2420
Bracket
"
3 790-438-1110
Screw
4 791-112-1180
Nut
5 790-101-2540
Washer
6 790-101-2102
Puller
(294kN
{30ton})
7 790-101-1102
Pump
1 791T-650-2410
N 2
Part name
2. Guide bushing
1) Remove seal (2).
2) Remove snap ring (3).
DISASSEMBLY
1. Center bushing
1) Remove center bushing (1).
30-202
"
2 "
3) Set tool N2 and remove side bushing (4)

from equalizer bar (5).
D375A-5
ASSEMBLY
1. Side bushing
1) Set side bushing (4) and tool N2 and press fit
side bushing (4) to equalizer bar (5).
2 Outside of side bushing:
Press fit the side bushing in the direction

shown below.

BAR BUSHING

After installing the snap ring, fill parts "c"
before and after the side bushing with
grease (G2-LI).
2 Amount of grease to be supplied to
side bushing: 0.3
3) Using a press, press fit seal (2).

Press fitting force for seal:
9.8 - 29.4 kN {1 - 3 tons}
Press fit the seal so that its metallic part
will not be projected from the equalizer
bar end.
2 Seal lip: Grease (G2-LI)
i)
Set split (mating) face "a" of the outer

bushing on the level.
ii) Set grease holes "b" of the inner
bushing and outer bushing diagonally.
Press fitting force for side bushing:
34.3 - 73.5 kN {3.5 - 7.5 tons}
2. Center bushing
Using the press, press fit bushing (1).
2 Outside of center bushing:

Press fitting force for center bushing:
4.9 - 186.2 kN {5 - 19 tons}
D375A-5
30-203
2 "
"

BAR BUSHING

N2-1 Bracket
N2-2 Bracket
30-204
"
2 "
D375A-5

SEGMENT TOOTH
REMOVAL AND
INSTALLATION OF
SEGMENT TOOTH
REMOVAL
INSTALLATION
1. Stop the machine in a position where the segment tooth can be removed (between the chute
and track frame).

2 Seat of segment tooth mounting nut:
3 Segment tooth mounting nut:
1,813 98 Nm {185 10 kgm}
3. Remove the mounting bolts and segment tooth

(3).
Before removing the all mounting bolts, insert bar 1 in the upper mounting bolt hole
and move and remove the segment tooth
outward.
4
D375A-5
Segment tooth: 35 kg
30-205
2 "
"
REMOVAL AND INSTALLATION OF HYDRAULIC

TANK ASSEMBLY
REMOVAL AND
INSTALLATION OF
HYDRAULIC
TANK ASSEMBLY
REMOVAL
Lower the work equipment to the ground and release the residual pressure from the piping, refe r r i n g t o T E S T I N G A N D A D J U S T I N G ,
Releasing residual pressure from hydraulic circuit. Then, loosen the hydraulic oil filler cap to
release the internal pressure of the hydraulic
tank.
5. Disconnect the 2 PPC hoses and 3 main hoses

(5) from the blade lift valve.
The PPC hoses are classified by the color
q1
bands.
1. Drain the oil from the hydraulic tank.

6
Hydraulic tank: 230
2. Remove operator's cab right cover (1).
6. Open hydraulic tank front cover (6) and disconnect hoses (7) and (8) from the blade lift valve.
Move the disconnected hoses toward the operator's cab.
3. Disconnect PPC charge valve (2) from the hydraulic tank.

Move the PPC charge valve toward the floor
frame.
30-206
"
2 "
D375A-5
7. Disconnect 6 PPC hoses (9), 4 rear main hoses

(10), and 4 front main hoses/tubes (11) from the
blade tilt and ripper Lo valve.
q2
bands.

TANK ASSEMBLY
10. Lift off hydraulic tank assembly (16).

4
Hydraulic tank assembly: 380 kg
q3
8. Disconnect return hose (12) and suction tube

(13) from the hydraulic tank.
9. Remove hydraulic tank front cover (14) and disconnect return hose (15).
D375A-5
30-207
2 "
"

TANK ASSEMBLY
INSTALLATION
q1
q2
The connecting positions of the PPC hoses

are indicated by the band colors on their
quick couplers. When connecting them,
confirm them by the band colors.
3 Hydraulic tank mounting bolt:

151.9 24.5 Nm {15.5 2.5 kgm}
q3
Refilling with oil (Hydraulic tank)

Add oil through the oil filler to the specified level.
system. Then, check the oil level again.
Bleeding air
Bleeding the air from the piping.
For details, see TESTING AND ADJUSTING,
Bleeding air from hydraulic cylinder.
Distinguishing color bands

(View from operators cad)
A. Transparent
B. Red/White
C. Black/Blue
D. Brown
E. Black
F. Green
G. White
H. Yellow
30-208
"
2 "
D375A-5
REMOVAL AND INSTALLATION OF WORK

EQUIPMENT AND PPC PUMP ASSEMBLY
REMOVAL AND
INSTALLATION OF WORK
EQUIPMENT
AND PPC PUMP ASSEMBLY
REMOVAL
tank.
7. Sling work equipment pump assembly (5) temporarily and remove the mounting bolts, then remove the work equipment pump assembly.
4
Work equipment and PPC pump

assembly: 45 kg

6
Hydraulic tank: 230
2. Remove the floor frame assembly. For details,

see REMOVAL OF FLOOR FRAME ASSEMBLY.
3. Disconnect hydraulic oil temperature sensor
connector (CN-452) (1).
4. Disconnect 2 hoses (2).
5. Disconnect 4 delivery hoses (3).
INSTALLATION
6. Disconnect suction tube (4).

Remove the 2 clamps and move the coupling
toward the pump to disconnect the suction
tube.
3 Suction tube clamp bolt:

26.95 2.45 Nm {2.75 0.25 kgm}
D375A-5

30-209
2 "
"
REMOVAL AND INSTALLATION OF BLADE

LIFT VALVE ASSEMBLY
REMOVAL AND
INSTALLATION OF BLADE
LIFT VALVE ASSEMBLY
REMOVAL
tank.
4. Open hydraulic tank front cover (4) and disconnect hoses (5) and (6).

6
Hydraulic tank: 230
2. Remove operator's cab right cover (1).
5. Sling work blade lift valve (7) temporarily and remove the mounting bolts. Then, remove the
blade lift valve assembly.
4
Blade lift valve assembly: 60 kg
3. Disconnect 2 PPC hoses (2) and 3 main hoses

(3).
q1
bands.
30-210
"
2 "
D375A-5
REMOVAL AND INSTALLATION OF BLADE

LIFT VALVE ASSEMBLY
INSTALLATION
q1


A. Transparent
B. Red/White

Bleeding air
Bleed air from the piping. For details, see TESTING AND ADJUSTING, Bleeding air from hydraulic cylinders.
D375A-5
30-211
2 "
"

BLADE LIFT VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BLADE LIFT VALVE

ASSEMBLY
This chapter deals only with precautions to be

followed when reassembling the Blade Lift Valve
Assembly.
ASSEMBLY
Clean the all parts and check them for dirt or
damage. Coat their sliding surfaces with engine
oil before installing.
1. Assembly of shuttle valve assembly
Install ball (31) and fit the O-ring and plug (30).
3 Plug:
34.3 4.9 Nm {3.5 0.5 kgm}
4. Assembly of main relief and shuttle valve assembly

Fit the O-ring and main relief and shuttle valve
assembly (18).
Tighten the mounting bolts in the order of 1
-4.
3 Mounting bolt:
1st time:
34.3 4.9 Nm {3.5 0.5 kgm}
2nd time:
66.15 7.35 {6.75 0.75 kgm}
2. Assembly of check valve assembly

Install valve (29) and spring (28) and fit the Oring and plug (27).
3 Plug:367.5 24.5 Nm {37.5 2.5 kgm}
3. Assembly of suction valve assembly

Install valve (26) and spring (25) and fit the Oring and plug (24).
3 Plug:514.5 24.5 Nm {52.5 2.5 kgm}
30-212
"
2 "
D375A-5

BLADE LIFT VALVE ASSEMBLY
If the main relief valve was disassembled,

adjust it after installing the valve assembly to
the machine body, referring to TESTING
AND ADJUSTING, Measuring and adjusting
work equipment oil pressure.
5. Assembly of demand valve assembly
1) Install seal (17), spool (16), O-ring, and case
(15).
3 Mounting bolt:
186.2 9.8 Nm {19 1 kgm}
2) Install spring (14) and case (13).
3 Mounting bolt:
186.2 9.8 Nm {19 1 kgm}
6. Assembly of main spool assembly

1) Install spool (12), O-ring, and case (11).
2) Install retainer (10), spring (9), O-ring, and
case (8).
3) Install retainer (7), spacer (6), spring (5), retainer (4), and washer (3) and tighten bolts
(2).
3 Mounting bolt:
110.25 12.25 Nm
{11.25 1.25 kgm}
Tighten the bolts with the spool installed
in the body.
4) Install the O-ring and case (1).
D375A-5
30-213
2 "
"
DISASSEMBLY AND ASSEMBLY OF BLADE TILT

AND RIPPER LOW VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BLADE TILT AND RIPPER

LOW VALVE ASSEMBLY
30-214
"
2 "
D375A-5
DISASSEMBLY AND ASSEMBLY OF BLADE TILT

AND RIPPER LOW VALVE ASSEMBLY

followed when reassembling the Blade Tilt and
Ripper Low Valve Assembly.
ASSEMBLY
1. Assembly of shuttle valve assembly
1) Install ball (20) and seat (19) to plug (18).
2) Install the O-ring and plug (18).
3 Plug:
34.3 4.9 Nm {3.5 0.5 kgm}
2. Assembly of check valve assembly

1) Install valve (17) and spring (16).
2) Install the O-ring, seat (15), and bar (14) and
tighten bolts (13).
3. Assembly of main relief valve assembly
Install the O-ring and main relief valve assembly
(12).
3 Main relief valve assembly:
83.3 14.7 Nm {8.5 1.5 kgm}
If the main relief valve was disassembled,

adjust it after installing the valve assembly to
the machine body, referring to TESTING
AND ADJUSTING, Measuring and adjusting
work equipment oil pressure.
4. Assembly of spool assembly
1) Install spool (10) to body (11).
2) Set retainer (9), spacers (8) and (7), spring
(6), retainer (5), and washer (4) and tighten
bolts (3).
Tighten the bolts with the spool installed
in the body.
3 Mounting bolt:
34.3 4.9 Nm {3.5 0.5 kgm}

D375A-5
30-215
2 "
"

RIPPER HIGH VALVE ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RIPPER HIGH VALVE

ASSEMBLY
30-216
"
2 "
D375A-5

followed when reassembling the Ripper High
Valve Assembly.
ASSEMBLY
1. Install valve (23), spring (22), seat (21), O-ring,
and plug (20).
3 Plug:
514.5 24.5 Nm {52.5 2.5 kgm}

RIPPER HIGH VALVE ASSEMBLY
5. Assembly of constant-differential pressure

valve assembly
1) Install spool (9).
2) Set retainer (8), spring (7), and retainer (6) to
the spool and install plug (5).
Be sure to tighten the plug with the spool installed in the valve.
6. Install ball (4), O-ring, and plug (3).
3 Plug: 34.3 4.9 Nm {3.5 0.5 kgm}
7. Install the O-ring and blocks (2) and (1).
2. Install check valve (19), spring (18), O-ring, and

plug (17).
3 Plug: 127.4 19.6 Nm {13 2 kgm}
3. Assembly of ripper lift high valve assembly

1) Install spool (16).
2) Set retainer (15) and spring (14) to the spool
and install the O-ring and plug (13).
3 Plug:
66.15 7.35 {6.75 0.75 kgm}
3) Set retainer (12) and spring (11) to the spool

and install the O-ring and plug (10).
3 Plug:
66.15 7.35 {6.75 0.75 kgm}
Be sure to tighten the plugs with the

spool installed in the valve.
4. Assembly of ripper tilt high valve assembly
Assemble the ripper tilt high valve assembly according to the assembly procedure for the ripper
lift high valve assembly.
D375A-5
30-217
2 "
"
DISASSEMBLY AND ASSEMBLY OF PPC CHARGE

VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF PPC CHARGE
VALVE ASSEMBLY
followed when reassembling the PPC Charge
Valve Assembly.
ASSEMBLY
Check the all parts for dirt or damage. Coat their
sliding surfaces with engine oil before installing.
1. Install plugs (13) and (12).
2. Install poppet (11) and spring (10) to valve body
(1), then tighten plug (9).
When installing the spring, check its free
length.
Free length of spring: 25.3 mm
3. Install poppet (8) and spring (7) to valve body (1),
then tighten plug (6).
When installing the spring, check its free
length.
Free length of spring: 20.6 mm
4. Install strainer (5) and plug (4).
Tighten the strainer to the following torque
and caulk it by 2 places.
3 Strainer:
7.35 0.49 Nm {0.75 0.05 kgm}
5. Tighten relief valve (3) into valve body (1).
3 Relief valve:
53.9 4.9 Nm {5.5 0.5 kgm}
6. Install accumulator (2) to valve body (1).
30-218
"
2 "
D375A-5
DISASSEMBLY AND ASSEMBLY OF BLADE PPC

VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF BLADE PPC
VALVE ASSEMBLY
followed when reassembling the Blade PPC
Valve Assembly.
ASSEMBLY
1. Install the blade RAISE valve
1) Install the blade RAISE valve
2) Install the blade RAISE valve
Install spring (37) with its small seat diameter (inside diameter) end on the
shim (38) side.
3) Install spring (36), retainer (35), piston (34),
spring (33), and piston (32).
When installing piston (34), apply grease
(G2-LI) to the outside of the piston and
the inside of the body hole.
(G2-LI) to the inside of the body hole.
2. Install the blade LOWER valve.
1) Install valve (31) to body (18).
2) Install shim (30) and spring (29) to valve
(31).
shim (30) side.
3) Install spring (28), retainer (27), piston (26),
shim (25), retainer (24), ball (23), collar (22),
spring (21), spacer (20), and piston (19).
3. Install the blade tilt valve.
1) Install valve (17) to body (18).
2) Install shim (16) and spring (15) to valve
(17).
shim (16) side.
D375A-5
30-219
2 "
"
DISASSEMBLY AND ASSEMBLY OF BLADE PPC

VALVE ASSEMBLY
3) Install spring (14), retainer (13), and pistons

(12) and (11).
4. Install orifice (10).
3 Orifice:
11.8-14.7 Nm {1.2-1.5 kgm}

5. Install the O-ring and plate (9).
6. Install the O-ring and body (8).
7. Install the O-ring to collar (7) and install them to
body (8), then install seal (6).
8. Install plate (5).
3 Mounting bolt:
11.8-14.7 Nm {1.2-1.5 kgm}
9. Install joint (4).

When installing the joint, apply adhesive (LT2) to the female threads hole of body (8).
3 Joint:
44.1 4.9 Nm {3.5 0.5 kgm}
Apply grease (G2-LI) to the rocking part of

the joint.
10. Install boot (3) and disc (2) and secure them with
nut (1).
Apply grease (G2-LI) to the contact surfaces
of disc (2) and pistons (32), (19), and (11).
3 Nut:
112.7 14.7 Nm {11.5 1.5 kgm}
After installing the disc, adjust its height, referring to TESTING AND ADJUSTING, Adjusting PPC valve.
30-220
"
2 "
D375A-5
DISASSEMBLY AND ASSEMBLY OF RIPPER

PPC VALVE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF RIPPER
PPC VALVE ASSEMBLY
followed when reassembling the Ripper PPC
Valve Assembly.
ASSEMBLY
1. Install valve (13) to body (14).
2. Install shim (12) and spring (11) to valve (13).
Install spring (11) with its small seat diameter
(inside diameter) end on the shim (12) side.
3. Install spring (10), retainer (9), and piston (8).
Springs (10) having different number of turns
are used for the following hydraulic ports.
Take care when installing them.
Port
Total number of turns
P1, P2
P3, P4
10.5
Each port position is stamped on the underside of the valve body.

2 Piston: Grease (G2-LI)
When installing piston (8), apply grease to

the outside of the piston and the inside of the
body hole.
4. Install the O-ring to collar (7) and install them to
body (14), then install seal (6).
5. Install plate (5).
3 Mounting bolt:
13.72 1.96 Nm {1.4 0.2 kgm}
6. Install joint (4).
2 Rocking part of joint: Grease (G2-LI)

2 Joint: Thread tightener (LT-2)
3 Joint: 44.1 5 Nm {4.5 0.5 kgm}

Observe the tightening torque for the joint.
7. Install boot (3) and disc (2) and secure them with
nut (1).
3 Nut: 112.7 14.7 Nm {11.5 1.5 kgm}

After installing the disc, adjust its height, referring to TESTING AND ADJUSTING, Adjusting PPC valve.
D375A-5
30-221
2 "
"
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC

CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF HYDRAULIC
CYLINDER ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.
3
U

model
cessity
!
790-201-1702
Push tool
kit
790-201-1841
Push tool
790-201-1861
Push tool
790-101-5021
Clip
01010-50816
Bolt
790-201-1500
Push tool
kit
790-201-1650
Plate
790-201-1670
Plate
790-101-5021
Clip
01010-50816
Bolt
796-720-1680
Ring
07281-01589
Clamp
796-720-1720
Ring
07281-02429
Clamp
796-720-1690
Ring
07281-02169
Clamp
790-102-2302
Wrench
6 790-330-1100
Multiwrench
790-101-1102
30-222
2 "
Pump
2. Quick drop valve assembly

Perform this procedure for only the blade lift
cylinder.
1) Remove quick drop valve assembly (1).
1
#
1. Cylinder tube
Remove the cylinder tube.
Expander
4 790-720-1000
"
Part name
Cylinder repair stand
1 790-502-1003
DISASSEMBLY
2) Disassemble the quick drop valve assembly

according to the following procedure.
i) Remove elbow (2).
ii) Remove spring (3), washer (4), and
valves (5) and (6), then pull out collar (7).
D375A-5
3. Piston rod assembly

1) Set cylinder assembly (8) to tool U1.
2) Remove head assembly (9).
3) Pull out piston rod assembly (10).
Put an oil pan under the cylinder to receive the oil.
4. Piston assembly
1) Set piston rod assembly (10) to tool U1.
D375A-5

CYLINDER ASSEMBLY

3) Remove the piston assembly.
4) Remove backup rings (13) and (14) and Oring (15).
5) Remove retainer (16).
6) Disassemble the piston assembly according

to the following procedure.
i) Remove wear ring (17).
ii) Remove piston ring (18).
30-223
2 "
"
5. Cylinder head assembly

1) Remove cylinder head assembly (19) from
the piston rod.

CYLINDER ASSEMBLY
ii) Remove snap ring (22) and tool (23).

iii) Remove packing (24) and bushing (25).
2) Disassemble the cylinder head assembly according to the following procedure.

i) Remove O-ring (20) and backup ring
(21).
30-224
"
2 "
D375A-5
ASSEMBLY

CYLINDER ASSEMBLY
v)
Install backup ring (21) and O-ring (20).
Apply engine oil to the sliding surfaces of each

part and install the packings, dust seals, and Orings, taking care not to damage them.
1) Assemble the cylinder head assembly according to the following procedure.
2) Install cylinder head assembly (19) to the

piston rod.
Using tool U2, press fit bushing (25) to

the head.
ii) Install packing (24).
iii) Using tool U3, press fit seal (23).
iv) Install snap ring (22).
i)
D375A-5
30-225
2 "
"
2. Piston assembly
1) Assemble the piston assembly according to
the following procedure.
i) Using tool U4, expand piston ring (18).
Set the piston ring to the tool and
turn the handle of the tool by 8 - 10
turns to expand the piston ring.
ii) Remove piston ring (18) from tool U4
and install it to the piston.

CYLINDER ASSEMBLY
2) Install retainer (16).

3) Install the O-ring and backup rings (14) and
(13).
Apply grease to the O-ring and backup
rings so that the backup rings will not
open.
4) Install piston assembly (12).
5) Install spacer (11) and tighten the mounting
bolts.
2 Mounting bolt:
3 Mounting bolt:
Blade lift:
66.5 7.5 Nm {6.75 0.75 kgm}
Blade tilt, ripper lift, ripper tilt:
176.5 19.5 Nm {18 2 kgm}
iii) Set tool U5 and shrink piston ring (18).

iv) Install wear ring (17) to the piston.

1) Set cylinder (8) to tool U1.
30-226
"
2 "
D375A-5
2) Install piston rod (10) to cylinder (8).

Apply grease to the sealing part of the
piston.
Push in the piston rod fully.
3) Push head assembly (9) in the cylinder and
tighten the mounting bolts.
Apply grease to the backup rings.

CYLINDER ASSEMBLY
2) Install quick drop valve assembly (1).

5. Cylinder tube
Install the cylinder tube.
4. Quick drop valve assembly

Perform this procedure for only the blade lift
cylinder.
1) Assemble the quick drop valve assembly according to the following procedure.
i) Install collar (7), valves (6) and (5), washer (4), and spring (3).
D375A-5
30-227
2 "
"
DISASSEMBLY AND ASSEMBLY OF RIPPER PIN

PULLER CYLINDER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF RIPPER PIN
PULLER
CYLINDER ASSEMBLY
SPECIAL TOOLS
Symbol
Part No.
1 790-502-1003
790-201-1702
2 790-201-1721
790-101-5021
Part name

model
cessity
Cylinder repair stand
Push tool
kit
Push tool
Clip
01010-50816
Bolt
790-201-1500
Push tool
kit
3 790-201-1530
790-101-5021
01010-50816
Plate
Grip
Bolt
1
#
796-720-1630
Ring
07281-00709
Clamp
790-102-2302
6 790-330-1100
790-101-1102
1. Cylinder assembly
1) Set pin puller cylinder assembly (1) to tool
U1.
2) Using tool U6, remove cylinder head assembly (2).
3) Remove piston rod (3) and cylinder head assembly (2) together.
Put an oil pan under the cylinder to receive the oil.
Expander
4 790-720-1000
5
DISASSEMBLY
Wrench
Multiwrench
Pump

1) Remove cylinder head assembly (2) from
piston rod (3).
30-228
"
2 "
D375A-5
2)
3)
4)
5)
Remove O-ring (5) and backup ring (6).

Remove O-ring (7).
Remove snap ring (8) and dust seal (9).
Remove rod packing (10) and bushing (11).

ASSEMBLY
Apply engine oil to the sliding surfaces of each
part and install the packings, dust seals, and Orings, taking care not to damage them.
1) Using tool U4, expand piston ring (12).
Set the piston ring to the tool and turn the
handle of the tool by 8 - 10 turns to expand
the piston ring.
2) Remove piston ring (12) from the tool and install it to piston rod (3).
3) Using tool U5, shrink piston ring (12).

Remove piston ring (12) from piston rod (3).
D375A-5
30-229
2 "
"

1) Using tool U2, press fit bushing (11) to cylinder head (4).
2) Using tool U3, press fit dust seal (9) to cylinder head (4).

6) Install cylinder head assembly (2) to piston

rod (3).
3. Cylinder assembly
1) Set the cylinder to tool U1 and support it with
block 1 .
2) Install piston rod (3) and cylinder head assembly (2) together.
Apply grease to the sealing part of the
piston.
Apply grease to the backup ring.
Push in the piston fully.
3) Using tool U6, tighten cylinder head 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).
30-230
"
2 "
D375A-5

BLADE ASSEMBLY
REMOVAL AND
INSTALLATION OF
BLADE ASSEMBLY
REMOVAL
Lower the work equipment to a level place and
set blocks 1 under both straight frames (6) securely.
q1
1. Remove cap (1) from the lift cylinder.
Check the quantity and thickness of the inserted shims.
3. Remove both covers (3).

4. Disconnect hose (4).
Plug the openings so that dirt will not enter
the piping.
5. Remove both trunnion caps (5).
6. Remove blade assembly (6).

q2
Start the engine and move the machine in reverse slowly to disconnect the blade assembly from the trunnion.
2. Sling lift cylinder assembly (2) temporarily. Start

the engine and retract the piston rod fully. Install
the cylinder fixing tool and fix the cylinder to the
radiator guard.
Bind the piston rod with wires so that it will
not come out.
Similarly, disconnect the cylinder on the opposite side from the blade.
Release the residual pressure from the piping,
referring to TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit.
Then, loosen the hydraulic oil filler cap to release
the internal pressure of the hydraulic tank.
D375A-5
30-231
2 "
"

BLADE ASSEMBLY
INSTALLATION
q1
Referring to TESTING AND ADJUSTING,

Adjusting semi-U tiltdozer, adjust the shims.
q2
Adjust height "b" and width "c" of both

straight frames to the following values with
block 1 , etc.
Trunnion height "b": Approx. 863 mm
Frame width "c": Approx. 3,484 mm

30-232
"
2 "
D375A-5

BLADE ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF
BLADE ASSEMBLY
DISASSEMBLY
Set blocks 1 and stands 2 securely under both
straight frames and blade to stabilize the blade.
3. Sling tilt cylinder assembly (4) temporarily and

remove the lock plate and pin (5).
4. Remove the lock plate and pin (6) and lift off tilt
cylinder assembly (4).
4
Tilt cylinder assembly: 380 kg
1. Remove right frame covers (1) and (2).

2. Disconnect tilt cylinder hose (3).
5. Set block 3 under right center brace (7) and remove the mounting bolts of cap (8) on the center
frame side.
Check the quantity and thickness of the
shims inserted under the cap.
D375A-5
30-233
2 "
"

BLADE ASSEMBLY
6. Sling right straight frame (9) temporarily and disconnect right center brace (7).
7. Remove the lock plate and pin (10) and lift off
right straight frame (9).
4
Straight frame: 1,150 kg
8. Sling tilt brace (11) temporarily and remove the

lock plate and pin (12).
9. Remove the lock plate and pin (13) and lift off tilt
brace (11).
4
11. Sling center brace (15) temporarily and remove

the mounting bolts and cap (16) and lift off both
center braces (15) and (7).
Check the quantity and thickness of the
shims inserted under the cap.
4
Center brace: 220 kg
12. Sling blade (17) and bring down the blade.

4
Blade: 4,900 kg
Tilt brace: 200 kg
10. Disconnect the left center brace and remove left

straight frame (14) similarly to steps 5 - 7 above.
30-234
"
2 "
D375A-5

BLADE ASSEMBLY
ASSEMBLY
Check the thickness and quantity of the shims
removed from each part during disassembly and
insert those shims to their original position.
For adjustment of the shims, see TESTING AND
ADJUSTING, Adjusting blade.
3. Sling right straight frame (9) and install pin (10)

and secure it with the lock plate.
4
Straight frame: 220 kg
4. Sling right straight frame (9) temporarily and set

the ball of right center brace (7) to right straight
frame (9).
1. Sling blade (17) and put a block, stand, etc. under it securely to stabilize it.
4
Blade: 4,900 kg
5. Insert the shims under cap (8) of right center

brace (7) and tighten the mounting bolts.
Standard shim thickness: 4.5 mm
2. Sling center brace (15) and set the shims and
tighten the mounting bolts of cap (16).
Set a block under the center brace according
to the height of the straight frame.
Standard shim thickness: 4.5 mm
4
Center brace: 220 kg
Install center brace (7) on the opposite side

similarly.
D375A-5
30-235
2 !
4

BLADE ASSEMBLY
6. Sling tilt cylinder assembly (4) and install pin (6)

and secure it with the lock plate.
10. Install left straight frame (14) similarly to steps 3

- 5 above and connect the left center brace.
11. Sling tilt brace (11) and install pin (13) and secure it with the lock plate.
7. Install pin (5) and secure it with the lock plate.
Tilt brace: 200 kg
12. Install pin (12) and secure it with the lock plate.
8. Connect tilt cylinder hose (3).

9. Install right frame covers (2) and (1).
13. Supplying grease
After finishing the assembly work, supply sufficient amount of grease to the parts shown in the
following figure.
2 Each part of work equipment:
Grease (G2-LI)
30-236
"
2 "
D375A-5
DISASSEMBLY AND ASSEMBLY OF GIANT

RIPPER ASSEMBLY
DISASSEMBLY AND
ASSEMBLY OF GIANT
RIPPER ASSEMBLY
DISASSEMBLY
1. Drive the machine over block 1 and lower the
blade to the ground.
Lock the brake securely.
2. Sling the shank temporarily and operate the pin
puller switch to pull out the shank pin.
3. Raise the ripper fully and lower and remove
shank (1) slowly.
4
Shank: 470 kg
Start the engine and retract the piston rod

fully and lower it onto the lift cylinder.
After stopping the engine, release the residual pressure from the piping, referring to
TESTING AND ADJUSTING, Releasing residual pressure from hydraulic circuit. Then,
loosen the hydraulic oil filler cap to release
the internal pressure of the hydraulic tank.
7. Disconnect 4 lift cylinder hoses (4), 4 tilt cylinder
hoses (5), and 2 pin puller cylinder hoses (6).
4. Set stand 2 between the arm and beam.
5. Sling the lift cylinder assembly and remove pin

(2).
Start the engine and retract the piston rod
fully and lower it onto the arm.
8. Sling tilt cylinder assembly (7) temporarily and

remove pin (8) and lift off tilt cylinder assembly
(7).
4
6. Sling the tilt cylinder assembly and remove pin

(3).
D375A-5
30-237
2 "
"
9. Sling lift cylinder assembly (9) temporarily and

remove pin (10) and lift off lift cylinder assembly
(9).
4
Lift cylinder assembly: 350 kg

RIPPER ASSEMBLY
ASSEMBLY
1. Sling and set arm (13) in position and install both
pins (14) and secure them with the lock plates.
4
Arm: 1,000 kg
Set a stand under the arm.
10. Sling beam (11) temporarily and remove both

pins (12) and lift off beam (11).
4
Beam: 2,000 kg
2. Sling and set beam (11) in position and install

both pins (12) and secure them with the lock
plates.
4
Beam: 2,000 kg
Set a stand under the beam.
11. Sling arm (13) temporarily and remove both pins

(14) and lift off arm (13).
4
30-238
"
2 "
Arm: 1,000 kg
D375A-5
3. Sling and set lift cylinder assembly (9) in position

and install pin (10) and secure it with the lock
plate.
4
Lift cylinder assembly: 350 kg

RIPPER ASSEMBLY
6. Sling the tilt cylinder assembly temporarily. Start

the engine and extend the piston rod to align it
with the pin hole. Install pin (3) and secure it with
the lock plate.
7. Sling the lift cylinder assembly temporarily. Start
the engine and extend the piston rod to align it
with the pin hole. Install pin (2) and secure it with
the lock plate.
8. Drive the machine over block 1 and lower the
blade to the ground.
Lock the brake securely.
4. Sling and set tilt cylinder assembly (7) in position

and install pin (8) and secure it with the lock
plate.
4
9. Raise the ripper a little and remove stand 2 .

10. Raise the ripper fully. Pass a wire through the
shank holder and raise shank (1) slowly to align
it with the pin hole. Operate the pin puller switch
to insert the shank pin.
11. Raise the blade and lower the machine body
from block 1 .
5. Connect 2 pin puller cylinder hoses (6), 4 tilt cylinder hoses (5), and 4 lift cylinder hoses (4).
D375A-5
12. Bleed air from the cylinders. For details, see

TESTING AND ADJUSTING, Bleeding air from
hydraulic cylinders.
30-239
2 "
"
REMOVAL AND INSTALLATION OF ROPS GUARD
REMOVAL AND
INSTALLATION OF ROPS
GUARD
REMOVAL
1. Sling ROPS guard (1) and remove 12 mounting
bolts (2).
q1
2. Lift off ROPS guard (1).
4
q2
ROPS guard: 766 kg
INSTALLATION
q1
3 ROPS guard mounting bolt:

1,715 196 Nm {175 20 kgm}
q2
Install the ROPS guard so that the fire extinguisher seats (3 pieces) will be on the right
of the machine body.
30-240
!
2 !
4
D375A-5
REMOVAL AND INSTALLATION OF OPERATOR'S

CAB ASSEMBLY
REMOVAL AND
INSTALLATION OF
OPERATOR'S CAB
ASSEMBLY
REMOVAL
6. Remove garnishes (7), (8), and (9).

1. Remove the ROPS guard. For details, see Removal of ROPS guard.
2. Remove the operator's cab left cover.
3. Disconnect wiring connectors (CN-19) (2) and
(CN-20, CN-21) (3).
Pull out the wires from inside of the operator's cab.
q1
4. Disconnect 4 window washer hoses (4).
Pull out the hoses from inside of the operator's cab.
7. Remove covers (10) on both sides and covers

(12) and (13).
5. Remove steps (5) and covers (6).

8. Remove angle (14) and in-cab angle (15).
D375A-5
30-241
2 !
4
9. Remove 19 mounting bolts and lift off operator's

cab assembly (16).
4
Operator's cab assembly: 420 kg

CAB ASSEMBLY
INSTALLATION
Before installing the cab, loosen the mounting
bolts of angle bar (14) and in-cab angle bar (15).
1. Seal
1) Fit seal (17) to guide plate (18) of the air conditioner box.
2 Part A on outside of seal
(Sealing face against cab):
Grease (G2-LI)
2) Sling operator's cab assembly (16) and stick

seal (19) to the mating face of the former.
30-242
!
2 !
4
D375A-5
DISA
2. Operators cab assembly

1) Lower the operators cab assembly to the
floor slowly.
Take care not to shift or damage the seal.
Check that the air conditioner duct seal
on the cab side is fitted to the air conditioner duct on the dashboard side and no
clearance is made.
Lower the cab carefully, since the clearance between the air conditioner duct on
the cab side and the monitor is little.
2) Tighten the mounting bolts temporarily.
Note that the bolt length and washer at
the door inlet are different.
Check that the seal between air conditioner bracket (20) and cab (21) is fitted
securely.
Check the joint B of the seal and floor
frame for gap.
If there is a clearance, remove the cab,
and then install it correctly. If the clearance is little, fill it with sealant, however.
D375A-5

CAB ASSEMBLY
Check that clearance a between cabside air conditioner duct (22) and monitor
(23) is the same on both sides.
Furthermore, check that seals (25) of
cab-side air conditioner ducts (22-1) are
fitted to both faces C of dashboard-side
air conditioner duct (26) and are not
shifted laterally.
30-242-1
4

CAB ASSEMBLY
If the clearance between cab-side air

conditioner duct (22-1) and monitor (23)
is not the same on both sides, loosen
mounting screws (27) of the cab-side air
conditioner duct and adjust the duct so
that the clearance will be the same on
both sides.
If cab-side air conditioner duct and dashboard-side air conditioner duct are shifted laterally, adjust their positions
similarly to the above.
3) Securely tighten the mounting bolts tightened temporarily in step 2).

4) Securely tighten the mounting bolts of angle
bar (14) and in-cab angle bar (15).
After the above work, carry out installation from
step 7 in reverse order to removal.
q1
When connecting the window washer hoses,

match the colors of their bands.
30-242-2
4
D375A-5
8. Disconnect blade PPC hoses (15), (16), (17),

q2
(18), and (19).
Move the hoses together toward the floor
frame.
REMOVAL AND INSTALLATION OF FLOOR FRAME
12. Remove window washer hose clamp (33).
9. Disconnect ripper PPC hoses (20), (21), (22),

(23), and (24).
q3
Move the hoses together toward the floor
frame.
10. Disconnect PPC hose (25).
13. Disconnect parking brake cable (34) from the lever and remove it from the bracket.
Before disconnecting the cable, check its inq4
stalled length.
11. Remove wiring connectors CN-FD5 (26), CNBWR (27), CN-USB (28), CN-FSB (29), CN-TL1
(30), CN-19 (31), and CN-SX8 (32).
Disconnect CN-TL1 from inside of the floor.
30-244
"
2 "
14. Disconnect brake pedal linkage (35) from the

turnbuckle.
q5
Before disconnecting the linkage, check the
installed length of the brake rod.
The turnbuckle has opposite threads.
D375A-5
15. Remove armrest (36).
19. Disconnect ground wire (40).
16. Remove right console (37).

Disconnect wiring connectors (CN-262, CN263) inside the console.
Before removing the console, remove the lever boot from the console.
20. Remove 4 left front mounting bolts (41).

21. Remove 4 right front mounting bolts (42).
q7
q8
17. Remove left console cover (38).
22. Lift off floor frame assembly (45).

4
18. Remove 4 rear mounting bolts (39) from each

q6
side.
D375A-5
Floor frame assembly: 600 kg
Using a chain block, sling the floor frame assembly slowly, balancing it carefully.
After removing the floor frame assembly, remove the spacers on the right front floor
mount.
30-245
2 "
"
q2
INSTALLATION
q1
q3

Connect the hoses so carefully that they will

not be twisted.
When installing the air conditioner circuit
hoses, take care that dirt, dust, or water will
not enter them.
When connecting the air conditioner hoses,
check that the O-rings are fitted to their
adapters.
Apply sufficient amount of compressor oil
(Showa-Shell Suniso 4G or 5G) to the Orings.

A. Transparent
B. Red/White
C. Black/Blue
D. Brown
E. Black
F. Green
G. White
H. Yellow
3 Tightening torque for air conditioner
refrigerant piping
Thread size
Tightening torque
16 1.5
12.23 1.47Nm {1.35 0.15kgm}
22 1.5
22.05 2.45Nm {2.25 0.25kgm}
24 1.5
31.85 2.45Nm {3.25 0.25kgm}
M6 bolt (for receiver) 5.39 1.47Nm {0.55 0.15kgm}

M6 bolt
(for compressor)
30-246
"
2 "
9.8 1.96Nm {1.0 0.2kgm}
D375A-5
q4
Adjust the parking brake lever linkage. For

details, see TESTING AND ADJUSTING,
Adjusting PCCS (Steering, Forward/Reverse
travel, Gear shifting), parking brake lever
linkage.
q5
Adjust the brake pedal linkage. For details,

see TESTING AND ADJUSTING, Adjusting
brake pedal linkage.
3 Brake pedal linkage turnbuckle:
45.56 12.25 Nm
{4.76 1.25 kgm}
q6
q7
3 Rear mounting bolt:

338.1 39.2 Nm {34.5 4kgm}
3 Front mounting bolt:

338.1 39.2 Nm {34.5 4kgm}
q8
Charging air conditioner with refrigerant

gas
Using tool X, charge the air conditioner circuit with refrigerant (R134a).
Add water through the water filler to the
specified level. Run the engine to circulate
the water through the system. Then, check
the water level again.
D375A-5
30-247
2 "
"

DASHBOARD ASSEMBLY
7. Lift off dashboard assembly (9).

4
Dashboard assembly: 95 kg

refrigerant piping
Thread size
Tightening torque
16 1.5
12.23 1.47Nm {1.35 0.15kgm}
22 1.5
22.05 2.45Nm {2.25 0.25kgm}
24 1.5
31.85 2.45Nm {3.25 0.25kgm}

M6 bolt
(for compressor)
INSTALLATION
q1

not be twisted.
not enter them.
adapters.
(Showa-Shell Suniso 4G or 5G) to the Orings.
D375A-5
9.8 1.96Nm {1.0 0.2kgm}
Charging air conditioner with refrigerant gas

Using tool X, charge the air conditioner circuit
with refrigerant (R134a).
Add water through the water filler to the specified
through the system. Then, check the water level
again.
30-249
2 "
"
REMOVAL AND INSTALLATION OF MONITOR

PANEL ASSEMBLY
REMOVAL AND
INSTALLATION OF MONITOR
PANEL ASSEMBLY
REMOVAL
1. Remove mounting bolts, then open monitor panel assembly (1).
2. Disconnect connectors (CN-1, CN-2, CN-3, CN4, CN-5, CN-S01, CN-S02) (2).
3. Remove monitor panel assembly.
INSTALLATION
30-250
"
2 "
D375A-5
REMOVAL AND INSTALLATION OF AIR

CONDITIONER UNIT ASSEMBLY
9. Remove ducts (17) and (18).
12. Disconnect bracket (22) and clamp (23).
10. Remove monitor (19) and cover (20).
13. Disconnect relays (CN-R1) (24), (CN-R2) (25),

and (CN-R3) (26) in the right part of the dashboard and connector (CN-M26) (27).
11. Remove inside filter (21).

14. Remove air conditioner unit (28).
15. Remove blower motor (29).
30-252
"
2 "
D375A-5
REMOVAL AND INSTALLATION OF AIR

CONDITIONER UNIT ASSEMBLY
INSTALLATION
Charging air conditioner with refrigerant gas

Using tool X, charge the air conditioner circuit
with refrigerant (R134a).

Add water through the water filler to the specified
through the system. Then, check the water level
again.
q1

not be twisted.
not enter them.
adapters.
(Showa-Shell Sniso 4G or 5G) to the Orings.

refrigerant piping
Thread size
Tightening torque
16 1.5
12.23 1.47Nm {1.35 0.15kgm}
22 1.5
22.05 2.45Nm {2.25 0.25kgm}
24 1.5
31.85 2.45Nm {3.25 0.25kgm}

M6 bolt
(for compressor)
D375A-5
9.8 1.96Nm {1.0 0.2kgm}
30-253
2 "
"
90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ...................................................................................
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM ...................................................................................
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER) ...................................................
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER) ...................................................
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) .........................................
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) .........................................
ELECTRICAL CIRCUIT DIAGRAM 1/5 .....................................................................................................
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER ...........................................................
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB ....................................................................................
90- 2
90- 3
90- 4
90- 5
90- 6
90- 7
90- 9
90-11
90-13
90-15
90-17
90-19
90-20
D375A-5
90-1
4
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
1. Oil tank
37. R.H steering clutch
2. Power train oil strainer
38. R.H steering brake
3. Power train pump (BAL180)
39. L.H steering brake
4. Power train oil filter

Set pressure: 0.29 MPa {3.0 kg/cm2}
40. L.H steering clutch
5. Transmission lubrication pump (BAL112)
42. Transmission lubrication valve

6. Power train lubricating oil filter
41. Brake prevention valve
7. Main relief valve

Set pressure: 2.65 0.1 MPa {27.0 1.0 kg/cm2}
43. Transmission lubrication
8. Modulating relief valve (ECMV) for R clutch
45. Scavenging pump (BAR63 + 277)
9. Modulating relief valve (ECMV) for F clutch

10. Modulating relief valve (ECMV) for 3rd clutch
11. Modulating relief valve (ECMV) for 2nd clutch
12. Modulating relief valve (ECMV) for 1st clutch
13. Fill switch
Operating pressure: 0.26 MPa {2.7 kg/cm2}
14. 1st clutch
44. PTO lubrication

46. Solenoid valve (for ripper pin puller)
47. Pin puller cylinder
48. Steering case
A. Torque converter lockup pressure pick-up port
B. Torque converter stator clutch pressure pick-up
port
C. L.H steering clutch operating pressure pick-up
port
15. 2nd clutch
D. L.H steering brake operating pressure pick-up

port
16. 3rd clutch

17. R clutch
E. Transmission 2nd clutch operating pressure pickup port
18. F clutch
19. Pilot filter
20. Torque converter relief valve
21. Torque converter
2
+1
Set pressure: 1.3 +0.1
0 MPa {13 0 kg/cm }
22. Oil cooler
23. Steering clutch/brake lubrication

24. Torque converter case
25. Torque converter lockup valve
26. Lockup clutch modulating valve
Set pressure: 1.3 +0.1 MPa {13 +1 kg/cm2}
F. Transmission R clutch operating pressure pick-up

port
G. Transmission 3rd clutch operating pressure pickup port
H. Transmission F clutch operating pressure pick-up
port
J. R.H steering brake operating pressure pick-up
port
K. R.H steering clutch operating pressure pick-up
port
27. Torque converter lockup solenoid valve
L. Transmission 1st clutch operating pressure pickup port
28. Torque converter lockup clutch
M. Transmission main relief pressure pick-up port

N. Torque converter regulator pressure pick-up port
30. Stator clutch lubrication
P. Torque converter relief pressure pick-up port
31. Stator clutch

32. Parking brake valve
33. R.H steering ECMV
34. R.H brake ECMV
35. L.H brake ECMV
36. L.H steering ECMV
90-2
D375A-5
90
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
D375A-5
90-3
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
(TILTDOZER)
TILTDOZER
1. Hydraulic tank
1A. Oil filler cap
13E. Ripper lift constant differential pressure

valve
2. Strainer
13F. Shuttle valve
3. PPC charge pump (SAR(1) 022)
13G. Shuttle valve
4. PPC charge valve

13H. Suction valve (for ripper lift)
5. Accumulator
13K. Ripper tilt constant differential pressure

valve
7. PPC lock valve
13L. Ripper tilt constant differential valve
8. Blade control PPC valve
13M. Shuttle valve
8A. For blade lift

8B. For blade tilt
9. Ripper control PPC valve
13J. Ripper tilt HI valve
13N. Shuttle valve

14. Quick drop valve
15. R.H blade lift cylinder
9A. For ripper lift
16. L.H blade lift cylinder
9B. For ripper tilt
17. Blade tilt cylinder
10. Work equipment pump (SAR(4) 140 + (3) 071)
18. R.H ripper tilt cylinder
11. Blade control valve
19. R.H ripper lift cylinder
11A. Demand valve
20. L.H ripper lift cylinder
11B. Main relief valve

Set pressure: 20.6 MPa {210 kg/cm2}
21. L.H ripper tilt cylinder
11C. Shuttle valve
22. Hydraulic oil filter

11D. Check valve

11E. Check valve
11F. Blade lift valve
11G. Suction valve (for blade lift)
11H. Shuttle valve
12. Blade tilt, ripper LO valve
12B. Check valve
12C. Blade tilt valve
12D. Check valve
12E. Ripper tilt valve
12F. Check valve
12G. Ripper lift valve
12H. Shuttle valve
13. Ripper HI valve
13A. Check valve
13B. Check valve
13C. Ripper lift (HI) valve
13D. Ripper lift constant differential pressure
valve
90-4
4
D375A-5

TILTDOZER
For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D375A-5
90-5
4
(DUAL TILTDOZER)
DUAL TILTDOZER
1. Hydraulic tank
1A. Oil filler cap
13E. Ripper lift constant differential pressure

valve
2. Strainer
13F. Shuttle valve
3. PPC charge pump (SAR(1) 022)
13G. Shuttle valve
4. PPC charge valve

13H. Suction valve (for ripper lift)
5. Accumulator
13K. Ripper tilt constant differential pressure

valve

7. PPC lock valve
8. Blade control PPC valve
8A. For blade lift
8B. For blade tilt
9. Ripper control PPC valve
9A. For ripper lift
9B. For ripper tilt
10. Work equipment pump (SAR(4) 140 + (3) 071)
11. Blade lift control valve
11A. Demand valve
11B. Main relief valve
13J. Ripper tilt HI valve
13L. Ripper tilt constant differential pressure

valve
13M. Shuttle valve
13N. Shuttle valve
14. Quick drop valve
15. R.H blade lift cylinder
16. L.H blade lift cylinder
17. Pitch selector solenoid valve
18. Dual tilt selector solenoid valve
19. Blade tilt cylinder
20. Blade pitch cylinder
21. R.H ripper tilt cylinder
11C. Shuttle valve
22. R.H ripper lift cylinder
11D. Check valve
23. L.H ripper lift cylinder
11E. Check valve
24. L.H ripper tilt cylinder
11F. Blade lift valve
25. Hydraulic oil filter

11G. Suction valve (for blade lift)

11H. Shuttle valve
12. Blade tilt, ripper LO valve
12B. Check valve
12C. Blade valve
12D. Check valve
12E. Ripper tilt valve
12F. Check valve
12G. Ripper lift valve
12H. Shuttle valve
13. Ripper HI valve
13A. Check valve
13B. Check valve
13C. Ripper lift (HI) valve
13D. Ripper lift constant differential pressure
valve
90-6
4
D375A-5

DUAL TILTDOZER
For details of the pin puller cylinder, see POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.
D375A-5
90-7
4
ELECTRICAL CIRCUIT DIAGRAM 1/5
D375A-5
90-9
4
D375A-5
90-11
4
D375A-5
90-13
4
D375A-5
90-15
4
D375A-5
90-17
4
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER
D375A-5
90-19
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB
90-20
D375A-5

D375A 5 Workshop Manual

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D375A 5 Workshop Manual

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Available Formats

GENERAL

Semi U-tilt dozer

Semi U-tilt dozer

Ditto with ROPS cab + Air conditioner +

Seat belt + Perforated side cover + SSC

Minimum turning radius

Stability (front, rear, left, right)

With semi U-dozer

With semi U-dozer + Variable multishank ripper

Ditto with ROPS cab + air conditioner

With semi U-dozer

With semi U-dozer + Variable multishank ripper

With U dozer + Variable multi-shank

Bevel gear shaft

Spiral bevel gear type, lubricating oil splashing type

Wet type, multiple disc clutch type, spring-boosted

Wet type, multiple disc clutch type, spring-boosted

Spur gear 1-stage, planetary gear 1-stage deceleration

Rigid, balancing beam type

Assembly type, single grouser, 40 each side,

Power train + lubricating oil pump (tandem)

Gear type (BAL 180 + 112)

Scavenging pump (tandem)

Gear type (BAR 63 + 277)

PPC charge pump

Gear type (SAR(1) 022)

(work equipment pump and tandem)

(at engine speed of 1,800 rpm)

Single pilot spool type, with demand spool

For blade tilt, ripper LO

Triple pilot spool type

Double pilot spool type

Double acting piston type

Piston rod outside diameter

Max. distance between pins

Min. distance between pins

Max. distance between pins

Min. distance between pins

Left cylinder: 225, Right cylinder: 250

Piston rod outside diameter

(both right and left)

Max. distance between pins

(both right and left)

(both right and left)

Piston rod outside diameter

Max. distance between pins

Min. distance between pins

Piston rod outside diameter

Max. distance between pins

Min. distance between pins

(external installation type)

Hydraulic U-tilt dozer

Blade support method

Blade cutting angle variation

(from ground level)

Blade cutting angle

Max. lifting height

Blade cutting angle variation

(from ground level)

Blade cutting angle

Max. pitch angle

Blade cutting angle

Max. pitch angle

Blade cutting angle