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SEN05006-09

BULLDOZER

D375A -6
SERIAL NUMBERS

60001

and up

Notice of revision

Notice of revision
9th. revision
The affected pages are indicated by the use of the
following marks. It is requested that necessary actions must be taken to these pages according to the
list below.

2012/02
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Indication

Action required

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Replace

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Discard

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List of revised pages


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Mark

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Colophon

Revision
number

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Page

Revision
number

(07)
(07)
(07)
(07)
(07)
(07)
(07)
(07)
(09)

(04)
(04)

DRAFT
D375A-6
SEN05009-00

Bulldozer
Shop Manual

D375A-6

Machine model
D375A-6

Serial number
60001 and up

00 Index and Foreword

D375A-6

00-1

Shop Manual
Table of contents

Table of contents
Notice of revision.............................................................................................................................................

00 Index and Foreword


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

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01 Specification
Specification and technical data......................................................................................................................
Specification drawing ...................................................................................................................................
Specifications...............................................................................................................................................
Weight table .................................................................................................................................................
Table of fuel, coolant and lubricants ............................................................................................................

01 - 3
01 - 3
01 - 4
01 - 9
01 - 11

10 Structure,function and maintenance standard


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

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D375A-6
(04)

Shop Manual
Table of contents

Work equipment control ...............................................................................................................................


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

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20 Standard value table


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

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30 Testing and adjusting


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

D375A-6
(07)

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00-3

ShopManual
Table of contents

Power train ......................................................................................................................................................


Testing power train oil pressure...................................................................................................................
Adjusting transmission output speed sensor ...............................................................................................
Simple test procedure for brake performance..............................................................................................
Adjusting brake pedal and parking brake lever............................................................................................
Adjusting position of pccs lever console ......................................................................................................
Emergency escape method when there is failure in power train .................................................................
Undercarriage and frame ................................................................................................................................
Inspecting wear of sprocket .........................................................................................................................
Testing and adjusting track shoe tension.....................................................................................................
Hydraulic system .............................................................................................................................................
Measuring and adjusting work equipment oil pressure................................................................................
Testing control circuit main pressure ...........................................................................................................
Testing PPC valve output pressure .............................................................................................................
Adjusting play of PPC valve.........................................................................................................................
Testing output pressure of ripper pin-puller solenoid valve .........................................................................
Checking location of cause of hydraulic drift of blade and ripper.................................................................
Testing leakage inside work equipment cylinder .........................................................................................
Releasing remaining pressure in work equipment cylinders........................................................................
Bleeding air from work equipment cylinders ................................................................................................
Adjusting ripper lever position......................................................................................................................
Work equipment ..............................................................................................................................................
Adjusting work equipment lock lever............................................................................................................
Adjusting blade ............................................................................................................................................
Cab and its attachments..................................................................................................................................
Testing and adjusting operator's cab ...........................................................................................................
Testing and adjusting operator's seat isolator..............................................................................................
Electrial system ...............................................................................................................................................
Special functions of machine monitor (EMMS) ............................................................................................
Handling of voltage circuit of engine controller ............................................................................................
Adjustment method when controller has been replaced ..............................................................................
Preparation work for troubleshooting of electrical system ...........................................................................
Inspection procedure of diode......................................................................................................................
Handling of optional devices ........................................................................................................................
Request for opening ORBCOMM terminal...................................................................................................
Initialization procedures for VHMS controller...............................................................................................
Using method of KOMTRAX functions of ORBCOMM terminal...................................................................
Precautions for replacing VHMS controller ..................................................................................................
Pm Clinic service.............................................................................................................................................
Pm Clinic service .........................................................................................................................................

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40 Troubleshooting
General Information on troubleshooting ..........................................................................................................
Points to remember when troubleshooting ..................................................................................................
Sequence of events in troubleshooting........................................................................................................
Checks before troubleshooting ....................................................................................................................
Classification and procedures for troubleshooting .......................................................................................
Failure codes table.......................................................................................................................................
Phenomena and troubleshooting numbers ..................................................................................................
Information in troubleshooting table.............................................................................................................
Troubleshooting method for disconnecting wiring harness of pressure sensor system...............................
Connectors table and arrangement drawing................................................................................................
Connection table for connector pin numbers ...............................................................................................
T-branch box and T-branch adapter table ...................................................................................................
Fuse locations table .....................................................................................................................................
Troubleshooting by failure code ......................................................................................................................
Failure code [AB00MA] Battery Charge Abnormal ......................................................................................
Failure code [1380MW] Lock up clutch: Slip................................................................................................
Failure code [1500L0] Transmission clutch: Abnormal ................................................................................
Failure code [15E0MW] Transmission clutch: Slip.......................................................................................
Failure code [15SAL1] Forward clutch: Fill high ..........................................................................................
Failure code [15SALH] Forward clutch: Fill Low ..........................................................................................
Failure code [15SBL1] Reverse clutch: Fill high ..........................................................................................

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00-4

D375A-6
(07)

Shop Manual
Table of contents

Failure code [15SBLH] Reverse clutch: Fill Low..........................................................................................


Failure code [15SEL1] Speed 1st clutch: Fill high .......................................................................................
Failure code [15SELH] Speed 1st clutch: Fill Low .......................................................................................
Failure code [15SFL1] Speed 2nd clutch: Fill high ......................................................................................
Failure code [15SFLH] Speed 2nd clutch: Fill Low ......................................................................................
Failure code [15SGL1] Speed 3rd clutch: Fill high.......................................................................................
Failure code [15SGLH] Speed 3rd clutch: Fill Low ......................................................................................
Failure code [15SJL1] L/U: Fill high .............................................................................................................
Failure code [15SJLH] L/U: Fill low..............................................................................................................
Failure code [1800MW] P/T clutch: Slip.......................................................................................................
Failure code [2201L1] Right clutch: Fill high ................................................................................................
Failure code [2201LH] Right clutch: Fill low.................................................................................................
Failure code [2202L1] Left clutch: Fill high ..................................................................................................
Failure code [2202LH] Left clutch: Fill low ...................................................................................................
Failure code [2300NR] Brake Themal Load Abnormality.............................................................................
Failure code [2301L1] Right brake: Fill high ................................................................................................
Failure code [2301LH] Right brake: Fill low .................................................................................................
Failure code [2301NR] Steering Brake RH Themal Load Abnormality ........................................................
Failure code [2302L1] Left brake: Fill high...................................................................................................
Failure code [2302LH] Left brake: Fill low....................................................................................................
Failure code [2302NR] Steering Brake LH Themal Load Abnormality.........................................................
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection.................................................................
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit ....................................................................
Failure code [AA10NX] Air Cleaner Clogging ..............................................................................................
Failure code [B@BAZG] Eng Oil Press Low................................................................................................
Failure code [B@BAZK] Eng Oil Level Low.................................................................................................
Failure code [B@BCNS] Eng Water Overheat ............................................................................................
Failure code [B@BCZK] Eng Water Level Low ...........................................................................................
Failure code [B@CENS] T/C Oil Overheat ..................................................................................................
Failure code [B@HANS] Hyd Oil Overheat..................................................................................................
Failure code [B@HAZK] Hyd Oil Level Low.................................................................................................
Failure code [CA111] ECM Critical Internal Failure .....................................................................................
Failure code [CA115] Eng Ne and Bkup Speed Sens Error ........................................................................
Failure code [CA122] Chg Air Press Sensor High Error ..............................................................................
Failure code [CA123] Chg Air Press Sensor Low Error ...............................................................................
Failure code [CA131] Throttle Sensor High Error ........................................................................................
Failure code [CA132] Throttle Sensor Low Error .........................................................................................
Failure code [CA135] Eng Oil Press Sensor High Error ..............................................................................
Failure code [CA141] Eng Oil Press Sensor Low Error ...............................................................................
Failure code [CA144] Coolant Temp Sens High Error .................................................................................
Failure code [CA145] Coolant Temp Sens Low Error..................................................................................
Failure code [CA153] Chg Air Temp Sensor High Error ..............................................................................
Failure code [CA154] Chg Air Temp Sensor Low Error ...............................................................................
Failure code [CA187] Sens Supply 2 Volt Low Error ...................................................................................
Failure code [CA212] Eng Oil Temp Sensor High Error ..............................................................................
Failure code [CA213] Eng Oil Temp Sensor Low Error ...............................................................................
Failure code [CA221] Ambient Press Sens High Error ................................................................................
Failure code [CA222] Ambient Press Sens Low Error .................................................................................
Failure code [CA227] Sens Supply 2 Volt High Error ..................................................................................
Failure code [CA234] Eng Overspeed .........................................................................................................
Failure code [CA238] Ne Speed Sens Supply Volt Error.............................................................................
Failure code [CA263] Fuel Temp Sensor High Error ...................................................................................
Failure code [CA265] Fuel Temp Sensor Low Error ....................................................................................
Failure code [CA271] IMV/PCV1 Short Error...............................................................................................
Failure code [CA272] IMV/PCV1 Open Error...............................................................................................
Failure code [CA273] PCV2 Short Error ......................................................................................................
Failure code [CA274] PCV2 Open Error ......................................................................................................
Failure code [CA322] Inj #1 (L#1) Open/Short Error....................................................................................
Failure code [CA323] Inj #5 (L#5) Open/Short Error....................................................................................
Failure code [CA324] Inj #3 (L#3) Open/Short Error....................................................................................
Failure code [CA325] Inj #6 (L#6) Open/Short Error....................................................................................
Failure code [CA331] Inj #2 (L#2) Open/Short Error....................................................................................
Failure code [CA332] Inj #4 (L#4) Open/Short Error....................................................................................

D375A-6
(07)

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00-4-1

Shop Manual
Table of contents

Failure code [CA342] Calibration Code Incompatibility................................................................................


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

00-4-2

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D375A-6
(07)

Shop Manual
Table of contents

Failure code [DD12KB] Shift up Sw: Short circuit ........................................................................................


Failure code [DD13KA] Shift down Sw: Disconnection................................................................................
Failure code [DD13KB] Shift down Sw: Short circuit ...................................................................................
Failure code [DD14KA] Parking lever Sw: Dissconnection..........................................................................
Failure code [DD14KB] Parking lever Sw: Short circuit ...............................................................................
Failure code [DDB9L4] Reverse SW Signal disagreement..........................................................................
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection ......................................................................
Failure code [DDK3L4] Forward SW Signal disagreement..........................................................................
Failure code [DDK5KA] Shift switch disconnection......................................................................................
Failure code [DDK5KB] Shift switch short circuit .........................................................................................
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality .................................................................
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality ..................................................................
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ..................................................................
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit......................................................................
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection.......................................................................
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit ..........................................................................
Failure code [DDNALD] Blade lift up pressure SW abnormality ..................................................................
Failure code [DDNBLD] Ripper lift up pressure SW abnormality.................................................................
Failure code [DDNCLD] Ripper lift down pressure SW abnormality ............................................................
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality..................................................................
Failure code [DDNELD] Ripper tilt back pressure SW abnormality .............................................................
Failure code [DDNFLD] Blade lift down pressure SW abnormality..............................................................
Failure code [DDNLKA] Weq lock Sw: Disconnection .................................................................................
Failure code [DDNLKB] Weq lock Sw: Short circuit.....................................................................................
Failure code [DDT5KA] Neutral switch disconnection .................................................................................
Failure code [DDT5KB] Neutral switch short circuit .....................................................................................
Failure code [DDT5KQ] Lever SPEC selection signal disagreement ..........................................................
Failure code [DDTSL1] S/C: Fill high ...........................................................................................................
Failure code [DDTSLH] S/C: Fill low............................................................................................................
Failure code [DGE5KX] Ambient temp sensor abnormality .........................................................................
Failure code [DGS1KX] Hyd oil temp: signal abnormal ...............................................................................
Failure code [DGT1KA] T/C oil temp sensor: Abnormal ..............................................................................
Failure code [DGT1KX] T/C oil temp sensor: Abnormal ..............................................................................
Failure code [DGT5KA] F exhaust temp sensor disconnection ...................................................................
Failure code [DGT5KB] F exhaust temp sensor short circuit.......................................................................
Failure code [DGT6KA] R exhaust temp sensor disconnection...................................................................
Failure code [DGT6KB] R exhaust temp sensor short circuit ......................................................................
Failure code [DH21KA] Weq pressure sensor: Disconnection ....................................................................
Failure code [DH21KB] Weq pressure sensor: Short circuit ........................................................................
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection........................................................
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ...........................................................
Failure code [DHT3KX] T/M oil pressure sensor abnormality......................................................................
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection..................................................................
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit .....................................................................
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection................................................................
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ...................................................................
Failure code [DK10KA] Fuel control Dial: Disconnection.............................................................................
Failure code [DK10KB] Fuel control Dial: Short circuit ................................................................................
Failure code [DK30KA] ST lever 1: Disconnection ......................................................................................
Failure code [DK30KB] ST lever 1: Short circuit ..........................................................................................
Failure code [DK30KX] ST lever: Out of normal range ................................................................................
Failure code [DK30KZ] ST lever: Disconnection or short circuit ..................................................................
Failure code [DK30L8] ST lever: Signal mismatch ......................................................................................
Failure code [DK31KA] ST lever 2: Disconnection ......................................................................................
Failure code [DK31KB] ST lever 2: Short circuit ..........................................................................................
Failure code [DK40KA] Brake potentiometer: Disconnection ......................................................................
Failure code [DK40KB] Brake potentiometer: Short circuit ..........................................................................
Failure code [DK55KX] FR lever: Out of normal range................................................................................
Failure code [DK55KZ] FR lever: Disconnection or short circuit..................................................................
Failure code [DK55L8] FR lever: Signal mismatch ......................................................................................
Failure code [DK56KA] FR lever 1: Disconnection ......................................................................................
Failure code [DK56KB] FR lever 1: Short circuit..........................................................................................
Failure code [DK57KA] FR lever 2: Disconnection ......................................................................................

D375A-6
(07)

40 -340
40 -342
40 -344
40 -346
40 -348
40 -350
40 -352
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40 -358
40 -360
40 -362
40 -364
40 -366
40 -368
40 -370
40 -372
40 -374
40 -376
40 -378
40 -380
40 -382
40 -384
40 -386
40 -388
40 -390
40 -392
40 -394
40 -396
40 -398
40 -400
40 -402
40 -404
40 -406
40 -408
40 -410
40 -412
40 -414
40 -416
40 -418
40 -420
40 -422
40 -424
40 -426
40 -428
40 -430
40 -432
40 -434
40 -436
40 -438
40 -440
40 -440
40 -441
40 -442
40 -444
40 -446
40 -448
40 -450
40 -450
40 -451
40 -452
40 -454
40 -456

00-4-3

Shop Manual
Table of contents

Failure code [DK57KB] FR lever 2: Short circuit..........................................................................................


Failure code [DK60KA] Acceleration sensor: Disconnection .......................................................................
Failure code [DK60KB] Acceleration sensor: Short circuit...........................................................................
Failure code [DKH1KA] Pitch angle sensor: Disconnection.........................................................................
Failure code [DKH1KB] Pitch angle sensor: Short circuit ............................................................................
Failure code [DLF1KA] T/C out-speed sensor: Disconnection ....................................................................
Failure code [DLM3KA] Fan rev. sensor: Disconnection .............................................................................
Failure code [DLM3MB] Fan control: Decline ..............................................................................................
Failure code [DLT3KA] T/M out-speed sensor: Disconnection ....................................................................
Failure code [DLT3KB] T/M out-speed sensor: Abnormal ...........................................................................
Failure code [DW59KA] Blade dual selector SOL disconnection.................................................................
Failure code [DW59KB] Blade dual selector SOL short circuit ....................................................................
Failure code [DW59KY] Blade dual selector SOL hot short.........................................................................
Failure code [DW5AKA] Blade pitch selector SOL disconnection ...............................................................
Failure code [DW5AKB] Blade pitch selector SOL short circuit ...................................................................
Failure code [DW5AKY] Blade pitch selector SOL Short circuit ..................................................................
Failure code [DW7BKA] Fan rev EPC: Disconnection.................................................................................
Failure code [DW7BKB] Fan rev EPC: Short circuit ....................................................................................
Failure code [DWN3KA] Ssp solenoid: Disconnection.................................................................................
Failure code [DWN3KB] Ssp solenoid: Short circuit ....................................................................................
Failure code [DWN3KY] SSP solenoid: Short circuit ...................................................................................
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection....................................................................
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit .......................................................................
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit .......................................................................
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection ...................................................................
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit.......................................................................
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit.......................................................................
Failure code [DXH1KA] Lock-up ECMV: Disconnection ..............................................................................
Failure code [DXH1KB] Lock-up ECMV: Short circuit..................................................................................
Failure code [DXH1KY] Lock-up ECMV: Short circuit..................................................................................
Failure code [DXH4KA] 1st clutch ECMV: Disconnection............................................................................
Failure code [DXH4KB] 1st clutch ECMV: Short circuit ...............................................................................
Failure code [DXH4KY] 1st clutch ECMV: Short circuit ...............................................................................
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ..........................................................................
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit ..............................................................................
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit ..............................................................................
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ...........................................................................
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit...............................................................................
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit...............................................................................
Failure code [DXH7KA] R clutch ECMV: Disconnection..............................................................................
Failure code [DXH7KB] R clutch ECMV: Short circuit .................................................................................
Failure code [DXH7KY] R clutch ECMV: Short circuit .................................................................................
Failure code [DXH8KA] F clutch ECMV: Disconnection ..............................................................................
Failure code [DXH8KB] F clutch ECMV: Short circuit..................................................................................
Failure code [DXH8KY] F clutch ECMV: Short circuit..................................................................................
Failure code [DXH9KA] Right clutch ECMV: Disconnection ........................................................................
Failure code [DXH9KB] Right clutch ECMV: Short circuit............................................................................
Failure code [DXH9KY] Right clutch ECMV: Short circuit............................................................................
Failure code [DXHAKA] Left clutch ECMV: Disconnection ..........................................................................
Failure code [DXHAKB] Left clutch ECMV: Short circuit..............................................................................
Failure code [DXHAKY] Left clutch ECMV: Short circuit..............................................................................
Failure code [DXHBKA] Right brake ECMV: Disconnection ........................................................................
Failure code [DXHBKB] Right brake ECMV: Short circuit............................................................................
Failure code [DXHBKY] Right brake ECMV: Short circuit............................................................................
Failure code [DXHCKA] Left brake ECMV: Disconnection ..........................................................................
Failure code [DXHCKB] Left brake ECMV: Short circuit..............................................................................
Failure code [DXHCKY] Left brake ECMV: Short circuit..............................................................................
Failure code [DXJBKA] S/C ECMV: Disconnection .....................................................................................
Failure code [DXJBKB] S/C ECMV: Short circuit.........................................................................................
Failure code [DXJBKY] S/C ECMV: Short circuit.........................................................................................
Failure code [DY2HKA] Pre lub. motor: Disconnection................................................................................
Failure code [F@BBZL] ENG blow-by pressure high level ..........................................................................
Failure code [F@BYNR] F exhaust temp high level (2) ...............................................................................

00-4-4

40 -458
40 -460
40 -462
40 -464
40 -466
40 -468
40 -469
40 -470
40 -471
40 -472
40 -473
40 -474
40 -475
40 -476
40 -477
40 -478
40 -479
40 -480
40 -481
40 -482
40 -484
40 -486
40 -487
40 -488
40 -490
40 -491
40 -492
40 -494
40 -495
40 -496
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40 -500
40 -502
40 -503
40 -504
40 -506
40 -507
40 -508
40 -510
40 -511
40 -512
40 -514
40 -515
40 -516
40 -518
40 -519
40 -520
40 -522
40 -523
40 -524
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40 -527
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40 -535
40 -536
40 -538
40 -540
40 -541

D375A-6
(07)

Shop Manual
Table of contents

Failure code [F@BYNS] F exhaust temp high level (1) ...............................................................................


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

D375A-6
(07)

40 -542
40 -543
40 -544
40 -545
40 -545
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40 -550
40 -554
40 -556
40 -558
40 -560
40 -561
40 -562
40 -564
40 -565
40 -566
40 -566
40 -566
40 -567
40 -567
40 -568
40 -568
40 -569
40 -569
40 -569
40 -570
40 -572
40 -574
40 -576
40 -577
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40 -590
40 -596
40 -598
40 -600
40 -601
40 -601
40 -602
40 -604
40 -606
40 -607
40 -608
40 -609
40 -610
40 -611
40 -612
40 -612
40 -613
40 -614
40 -615
40 -616
40 -617
40 -617
40 -618
40 -618
40 -619
40 -619
40 -620
40 -620
40 -621
40 -621
40 -622
40 -622

00-4-5

Shop Manual
Table of contents

Troubleshooting of engine (S-mode)...............................................................................................................


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

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40 -624
40 -628
40 -630
40 -634
40 -636
40 -637
40 -638
40 -640
40 -642
40 -643
40 -644
40 -645
40 -646
40 -647
40 -649
40 -650
40 -651
used up
40 -652

50 Disassembly and assembly


General information on disassembly and assembly........................................................................................
How to read this manual ..............................................................................................................................
Coating materials list....................................................................................................................................
Special tools list ...........................................................................................................................................
Sketches of special tools .............................................................................................................................
Engine and cooling system .............................................................................................................................
Removal and installation of fuel supply pump assembly .............................................................................
Removal and installation of fuel injector assembly ......................................................................................
Removal and installation of cylinder head assembly ...................................................................................
Removal and installation of radiator guard assembly ..................................................................................
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)...................
Removal and installation of radiator.............................................................................................................
Removal and installation of hydraulic oil cooler ...........................................................................................
Removal and installation of aftercooler........................................................................................................
Removal and installation of engine assembly..............................................................................................
Removal and installation of engine hood assembly.....................................................................................
Removal and installation of engine front seal ..............................................................................................
Removal and installation of engine rear seal ...............................................................................................
Removal and installation of fan drive assembly...........................................................................................
Removal and installation of fan motor assembly .........................................................................................
Removal and installation of fuel tank assembly ...........................................................................................
Power train ......................................................................................................................................................
Removal and installation of damper assembly ............................................................................................
Disassembly and assembly of damper assembly ........................................................................................
Removal and installation of power train unit assembly ................................................................................
Disconnection and connection of power train unit assembly .......................................................................
Disassembly and assembly of PTO assembly.............................................................................................
Disassembly and assembly of torque converter assembly ..........................................................................
Disassembly and assembly of TORQFLOW transmission assembly ..........................................................
Disassembly and assembly of steering case assembly...............................................................................
Removal and installation of power train pump and lubrication pump assembly ..........................................
Removal and installation of scavenging pump assembly ............................................................................
Removal and installation of final drive assembly .........................................................................................
Disassembly and assembly of final drive assembly.....................................................................................
Undercarriage and frame ................................................................................................................................
Removal and installation of track frame assembly.......................................................................................
Removal and installation of idler assembly..................................................................................................
Disassembly and assembly of idler assembly .............................................................................................
Removal and installation of recoil spring assembly .....................................................................................
Disassembly and assembly of recoil spring assembly.................................................................................
Removal and installation of track roller assembly........................................................................................

50 - 4
50 - 4
50 - 6
50 - 9
50 - 16
50 - 24
50 - 24
50 - 28
50 - 33
50 - 49
50 - 54
50 - 59
50 - 61
50 - 62
50 - 63
50 - 70
50 - 73
50 - 75
50 - 79
50 - 81
50 - 83
50 - 86
50 - 86
50 - 90
50 - 93
50 -100
50 -109
50 -115
50 -125
50 -153
50 -169
50 -170
50 -171
50 -173
50 -186
50 -186
50 -191
50 -192
50 -196
50 -201
50 -203

00-4-6

D375A-6
(07)

Shop Manual
Table of contents

Disassembly and assembly of track roller assembly ................................................................................... 50 -206


Removal and installation of carrier roller assembly ..................................................................................... 50 -209
Disassembly and assembly of carrier roller assembly ................................................................................. 50 -210
Removal and installation of bogie assembly................................................................................................ 50 -214
Disassembly and assembly of bogie assembly ........................................................................................... 50 -219
Removal and installation of first bogie assembly ......................................................................................... 50 -221
Separation and connection of track shoe assembly .................................................................................... 50 -226
Overall disassembly and assembly of track shoe ........................................................................................ 50 -230
Link press press-fitting jig dimensions ......................................................................................................... 50 -247
Disassembly and assembly of one link assembly in the field ...................................................................... 50 -248
Disassembly and assembly of master link ................................................................................................... 50 -253
Removal and installation of pivot shaft assembly ........................................................................................ 50 -257
Removal and installation of equalizer bar .................................................................................................... 50 -258
Disassembly and assembly of equalizer bar bushing .................................................................................. 50 -262
Removal and installation of segment tooth .................................................................................................. 50 -264
Hydraulic system ............................................................................................................................................. 50 -266
Removal and installation of hydraulic tank assembly .................................................................................. 50 -266
Removal and installation of work equipment pump assembly ..................................................................... 50 -269
Removal and installation of fan pump assembly.......................................................................................... 50 -273
Removal and installation of control valve assembly .................................................................................... 50 -275
Disassembly and assembly of control valve assembly ................................................................................ 50 -277
Disassembly and assembly of blade PPC valve assembly.......................................................................... 50 -282
Disassembly and assembly of ripper PPC valve assembly ......................................................................... 50 -285
Disassembly and assembly of hydraulic cylinder assembly ........................................................................ 50 -287
Disassembly and assembly of ripper pin puller cylinder assembly .............................................................. 50 -295
Work equipment .............................................................................................................................................. 50 -298
Removal and installation of blade assembly................................................................................................ 50 -298
Disassembly and assembly of blade assembly ........................................................................................... 50 -300
Disassembly and assembly of giant ripper assembly .................................................................................. 50 -304
Cab and its attachments.................................................................................................................................. 50 -308
Removal and installation of ROPS guard .................................................................................................... 50 -308
Removal and installation of operators cab assembly.................................................................................. 50 -309
Removal and installation of floor frame assembly ....................................................................................... 50 -313
Removal and installation of air conditioner unit assembly ........................................................................... 50 -318
Removal and installation of operator's seat isolator ....................................................................................50-323-1
Disassembly and assembly of operator's seat isolator ................................................................................50-323-2
Electrical system ............................................................................................................................................. 50 -324
Removal and installation of transmission controller assembly and steering controller assembly................ 50 -324
Removal and installation of engine controller assembly .............................................................................. 50 -325
Removal and installation of VHMS controller assembly .............................................................................. 50 -327
Removal and installation of machine monitor assembly .............................................................................. 50 -328
60 Maintenance Standard
Engine and cooling system .............................................................................................................................
Engine mount...............................................................................................................................................
Cooling fan pump.........................................................................................................................................
Cooling fan motor.........................................................................................................................................
Power train ......................................................................................................................................................
Power train unit ............................................................................................................................................
Damper and universal joint ..........................................................................................................................
Torque converter and PTO ..........................................................................................................................
Main relief valve and torque converter relief valve.......................................................................................
Lockup clutch ECMV and stator clutch ECMV.............................................................................................
Scavenging pump ........................................................................................................................................
Transmission control....................................................................................................................................
Transmission................................................................................................................................................
Transmission lubricating oil relief valve .......................................................................................................
Power train and lubrication pump ................................................................................................................
Transfer, bevel gear shaft and steering unit ................................................................................................
Steering control valve ..................................................................................................................................
Steering clutch ECMV and steering brake ECMV........................................................................................
Parking brake valve .....................................................................................................................................
Final drive ....................................................................................................................................................

D375A-6
(07)

6060606060606060606060606060606060606060-

3
3
5
12
14
14
16
19
22
23
24
25
26
30
31
32
38
39
40
41

00-4-7

Shop Manual
Table of contents

Sprocket.......................................................................................................................................................
Undercarriage and frame ................................................................................................................................
Track frame..................................................................................................................................................
Idler cushion.................................................................................................................................................
Idler ..............................................................................................................................................................
Track roller ...................................................................................................................................................
Carrier roller .................................................................................................................................................
Track roller bogie .........................................................................................................................................
Track shoe ...................................................................................................................................................
Main frame ...................................................................................................................................................
Suspension ..................................................................................................................................................
Hydraulic system .............................................................................................................................................
PPC valve ....................................................................................................................................................
Hydraulic cylinder.........................................................................................................................................
Quick drop valve ..........................................................................................................................................
Work equipment pump.................................................................................................................................
Control valve ................................................................................................................................................
Self-pressure reducing valve .......................................................................................................................
Work equipment ..............................................................................................................................................
Cylinder stay ................................................................................................................................................
Blade............................................................................................................................................................
Cutting edge and end bit..............................................................................................................................
Ripper ..........................................................................................................................................................

6060606060606060606060606060606060606060606060-

44
46
46
48
50
52
54
55
56
60
62
67
67
72
75
76
79
85
87
87
88
92
94

80 Appendix
Air Conditioner.................................................................................................................................................
Caution about refrigerant .............................................................................................................................
Air conditioner component ...........................................................................................................................
Configuration and function of refrigeration cycle..........................................................................................
Outline of refrigeration cycle ........................................................................................................................
Air conditioner unit .......................................................................................................................................
Blower unit ...................................................................................................................................................
FRESH/RECIRC air changeover damper ....................................................................................................
Compressor .................................................................................................................................................
Condenser ...................................................................................................................................................
Receiver drier...............................................................................................................................................
Air conditioner control panel ........................................................................................................................
Procedure for testing and troubleshooting ...................................................................................................
Circuit diagram and arrangement of connector pins ....................................................................................
System diagram ...........................................................................................................................................
Part and connector locations .......................................................................................................................
Testing temperature control .........................................................................................................................
Testing FRESH/RECIC air changeover .......................................................................................................
Testing relay ................................................................................................................................................
Troubleshooting chart 1 ...............................................................................................................................
Troubleshooting chart 2 ...............................................................................................................................
Information in troubleshooting table.............................................................................................................
Troubleshooting for power supply system (Air conditioner does not operate) .............................................
Troubleshooting for compressor system (Air is not cooled).........................................................................
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) .........................
Troubleshooting for temperature control......................................................................................................
Troubleshooting for FRESH/RECIRC air changeover .................................................................................
Troubleshooting with gauge pressure..........................................................................................................
Connection of service tool............................................................................................................................
Precautions for disconnecting and connecting ............................................................................................
Handling of compressor oil ..........................................................................................................................

80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 80 -

3
3
4
6
7
10
14
15
16
17
18
20
22
24
26
28
32
32
34
36
38
40
42
44
48
54
56
58
60
62
64

90 Diagrams and Drawings


Hydraulic diagrams and drawings ...................................................................................................................
Symbols used in hydraulic circuit diagrams .................................................................................................
Power train hydraulic circuit diagram ...........................................................................................................
Hydraulic circuit diagram..............................................................................................................................

90 90 90 90 -

3
3
5
7

00-4-8

D375A-6
(07)

Shop Manual
Table of contents

Electrical diagrams and drawings.................................................................................................................... 90 - 9


Symbols use in electric circuit diagrams ...................................................................................................... 90 - 9
Electrical circuit diagram .............................................................................................................................. 90 - 13
Index................................................................................................................................................................ ........ 1

D375A-6
(07)

00-4-9

DRAFT
Table of contents

00-4-10
00-14

D375A-6
(02)

Forword and general information


Safety notice

Forword and general information


Safety notice

0 -3

Important safety notice


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

7) If welding repairs are needed, always have a


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

00-5

Forword and general information


Safety notice

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

00-6

5) When raising a heavy component (heavier


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

D375A-6
(09)

Forword and general information


Safety notice

12)When assembling or installing parts, always


tighten them to the specified torques. When
installing protective parts such as guards, or
parts which vibrate violently or rotate at high
speeds, be particularly careful to check that
they are installed correctly.
13)When aligning 2 holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
14)When measuring hydraulic pressure, check
that the measuring tools are correctly
installed.
15)Take care when removing or installing the
tracks of track-type machines. When
removing the track, the track separates
suddenly, so never let anyone stand at either
end of the track.
16)If the engine is operated for a long time in a
place which is not ventilated well, you may
suffer from gas poisoning. Accordingly, open
the windows and doors to ventilate well.
4. Precautions for slinging work and making
signals
1) Only one appointed worker must make
signals and co-workers must communicate
with each other frequently. The appointed
signaler must make specified signals clearly
at a place where he is well seen from the
operator's seat and where he can see the
working condition easily. The signaler must
always stand in front of the load and guide
the operator safely.
q Do not stand under the load.
q Do not step on the load.
2) Check the slings before starting sling work.
3) Keep putting on gloves during sling work.
(Put on leather gloves, if available.)
4) Measure the weight of the load by the eye
and check its center of gravity.
5) Use proper sling according to the weight of
the load and method of slinging. If too thick
wire ropes are used to sling a light load, the
load may slip and fall.
6) Do not sling a load with 1 wire rope alone. If
it is slung so, It may rotate and may slip out
of the rope. Install 2 or more wire ropes
symmetrically.
k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the
rope from its original winding position
on the load, which can result in a dangerous accident.

D375A-6
(09)

7) Limit the hanging angle to 60 , as a rule.


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

8) When installing wire ropes to an angular


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

00-7

Forword and general information


Safety notice

11)Do not use twisted or kinked wire ropes.


12)When lifting up a load, observe the following.
q Wind in the crane slowly until wire ropes
are stretched. When settling the wire
ropes with the hand, do not grasp them
but press them from above. If you grasp
them, your fingers may be caught.
q After the wire ropes are stretched, stop
the crane and check the condition of the
slung load, wire ropes, and pads.
q If the load is unstable or the wire rope or
chains are twisted, lower the load and lift
it up again.
q Do not lift up the load at an angle.
13)When lowering a load, observe the following.
q When lowering a load, stop it temporarily
at 30 cm above the floor, and then lower
it slowly.
q Check that the load is stable, and then remove the sling.
q Remove kinks and dirt from the wire
ropes and chains used for the sling work,
and put them in the specified place.
5. Precautions for using mobile crane
a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely.
6. Precautions for using overhead traveling
crane
k A hoist crane or similar device must be
used for lifting a heavy load (25 kg or
more).The weight of a part that is 25 kg or
more is indicated with the symbol "4" in
"Disassembly and assembly".
1) Before starting work, inspect the wire ropes,
brake, clutch, controller, rails, over wind stop
device, ground fault circuit interrupter, crane
collision prevention device, and power application warning lamp, and check safety.
2) Observe the signals for sling work.
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east,
west, south, and north) and the directions of
the control buttons without fail.
5) Do not sling a load at an angle. Do not move
the crane while the slung load is swinging.
6) Do not raise or lower a load while the crane
is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and lift
up a load to a safe height.

00-8

10)Place the control switch on a position where


it will not be an obstacle to work and
passage.
11)After operating the hoist, do not swing the
control switch.
12)Remember the position of the main switch so
that you can turn off the power immediately in
an emergency.
13)If the hoist stops because of a power failure,
turn the power switch OFF. When turning on
a switch which was turned OFF by the
ground fault circuit interrupter, check that the
devices related to that switch are not in operation state.
14)If you find an obstacle around the hoist, stop
the operation.
15)After finishing the work, stop the hoist at the
specified position and raise the hook to at
least 2 mabove the floor. Do not leave the
sling installed to the hook.
7. Selecting wire ropes
1) Select adequate ropes depending on the
weight of parts to be hoisted, referring to the
table below
Wire ropes
(Standard "Z" twist ropes without galvanizing)
(JIS G3525, No. 6, Type 6X37-A)
Nominal diameter
Allowable load
of rope
mm
kN
ton
10
8.8
0.9
12
12.7
1.3
14
17.3
1.7
16
22.6
2.3
18
28.6
2.9
20
35.3
3.6
25
55.3
5.6
30
79.6
8.1
40
141.6
14.4
50
221.6
22.6
60
318.3
32.4

a The allowable load is one-sixth of the


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

D375A-6
(09)

Forword and general information


Safety notice

8. Precautions
for
disconnecting
and
connecting hoses and tubes in an air conditioner circuit
1) Disconnection
k Although the refrigerant (refrigerant
gas: R134a) used on the machine's air
conditioner is less destructive to the
ozone layer for environmentally friendliness, it is not allowed to be vented
into the atmosphere as is.Whenever
disconnecting the air conditioner gas
circuit, be sure to recover the refrigerant gas to reuse it.
a Ask a gualified person for collecting and
filling operation of refrigerant (R134a).
a Never release the refrigerant (R134a) to
the atmosphere.
k If the refrigerant gas gets in your eyes
or contacts your skin, you may lose
your sight or your skin may be frozen.Whenever recovering or adding
refrigerant gas, you must put on safety
glasses, safety gloves and long
sleeved clothes.
The refrigerant gas must be recovered
and added by a qualified person.

a For tightening torque, see the precautions for installation in each section of
"Disassembly and assembly".

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

D375A-6
(09)

00-9

DRAFT
Forword and general information
How to read the shop manual

How to read the shop manual


q
q
q

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

Composition of shop manual

This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains table of contents, and safety and basic information. If any revision of the shop manual is made, the LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgment criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60.Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80.Appendix
The section explains the equipment which can not be included in the other sections. This section explains
the structure, function, testing, adjusting, and troubleshooting fo the equipment.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.

00-10

D375A-6

DRAFT
Forword and general information
How to read the shop manual

Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.

Revision and distribution

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

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

Revision number
When a manual is revised, revision number of each page is increased by 1.
(Example: (1),(2),(3)...)

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

Symbols

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

Item

Safety

Caution

Special technical precautions or other precautions for preserving standards are


necessary when performing work.

Weight

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


wire, or when working posture is important, etc.

Remarks

Special safety precautions are necessary when performing work.

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

Coat

Oil, coolant

Drain

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

Places where oil, etc. must be added, and capacity.

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

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

D375A-6

00-11

DRAFT
Forword and general information
Explanation of terms for maintenance standard

Explanation of terms for maintenance standard


The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria.
1. Standard size and tolerance
q To be accurate, the finishing size of parts is a
little different from one to another.
q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated.
q The above size set temporarily is called the
"standard size" and the range of difference
from the standard size is called the "tolerance".
q The tolerance with the symbols of + or is indicated on the right side of the standard size.
Example:
Standard size

Tolerance
- 0.022
- 0.126

120

a The tolerance may be indicated in the text


and a table as [standard size (upper limit of
tolerance/lower limit of tolerance)].
Example) 120 (0.022/0.126)
Usually, the size of a hole and the size of the
shaft to be fitted to that hole are indicated by
the same standard size and different tolerances of the hole and shaft. The tightness of
fit is decided by the tolerance.
Indication of size of rotating shaft and hole
and relationship drawing of them

Example:
Standard size
60

00-12

Tolerance
Shaft
- 0.030
- 0.076

Hole
+ 0.046
0

D375A-6

DRAFT
Forword and general information
Explanation of terms for maintenance standard

2. Standard clearance and standard value


q The clearance made when new parts are assembled is called the "standard clearance",
which is indicated by the range from the minimum clearance to the maximum clearance.
q When some parts are repaired, the clearance
is generally adjusted to the standard clearance.
q A value of performance and function of new
products or equivalent is called the "standard
value", which is indicated by a range or a target value.
q When some parts are repaired, the value of
performance/function is set to the standard
value.
3. Standard interference
q When the diameter of a hole of a part shown
in the given standard size and tolerance table
is smaller than that of the mating shaft, the
difference between those diameters is called
the "interference".
q The range (A B) from the difference (A) between the minimum size of the shaft and the
maximum size of the hole to the difference
(B) between the maximum size of the shaft
and the minimum size of the hole is the "standard interference".
q After repairing or replacing some parts, measure the size of their hole and shaft and
check that the interference is in the standard
range.

5. Clearance limit
q Parts can be used until the clearance between them is increased to a certain limit.
The limit at which those parts cannot be used
is called the "clearance limit".
q If the clearance between the parts exceeds
the clearance limit, they must be replaced or
repaired.
6. Interference limit
q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the
"interference limit".
q The interference limit shows the repair limit of
the part of smaller tolerance.
q If the interference between the parts exceeds
the interference limit, they must be replaced
or repaired.

4. Repair limit and allowable value or allowable


dimension
q The size of a part changes because of wear
and deformation while it is used. The limit of
changed size is called the "repair limit".
q If a part is worn to the repair limit, it must be
replaced or repaired.
q The performance and function of a product
lowers while it is used. A value which the
product can be used without causing a problem is called the "allowable value" or "allowable dimension".
q If a product is worn to the allowable value, it
must be checked or repaired. Since the permissible value is estimated from various tests
or experiences in most cases, however, it
must be judged after considering the operating condition and customer's requirement.

D375A-6

00-13

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

Handling of electric equipment and hydraulic components


To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be
carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at
improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic components" (particularly gear oil and hydraulic oil).
Points to remember when handling electric equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wires connecting
one component to another component, connectors used for connecting and disconnecting one
wire from another wire, and protectors or tubes
used for protecting the wires.
Compared with other electrical components
fitted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects of
rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they are
frequently removed and installed again, so they
are likely to suffer deformation or damage. For
this reason, it is necessary to be extremely
careful when handling wiring harnesses.
2. Main failures occurring in wiring harness
1) Defective contact of connectors (defective
contact between male and female connectors)
Problems with defective contact are likely to
occur because the male connector is not
properly fitted into the female connector, or
because one or both of the connectors is
deformed or the position is not correctly
aligned, or because there is corrosion or
oxidization of the contact surfaces. The
corroded or oxidized contact surfaces may
become shiny again (and contact may
become normal) by connecting and disconnecting the connector about 10 times.
2) Defective crimping or soldering of connectors
The pins of the male and female connectors
are connected to wires by crimping or
soldering. If excessive force is applied to the
wire, the joint is separated to cause defective
contact or the wire is broken.

00-14

D375A-6

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

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

4) High-pressure water entering connector


The connector is designed to make it difficult
for water to enter (drip-proof structure), but if
high-pressure water is sprayed directly on
the connector, water may enter the
connector, depending on the direction of the
water jet.
Accordingly, take care not to splash water
over the connector.
The connector is designed to prevent water
from entering, but at the same time, if water
does enter, it is difficult for it to be drained.
Therefore, if water should get into the
connector, the pins will be short-circuited by
the water, so if any water gets in, immediately
dry the connector or take other appropriate
action before passing electricity through it.
5) Oil or dirt stuck to connector
If oil or grease are stuck to the connector and
an oil film is formed on the mating surface of
the male and female pins, the oil will not let
the electricity pass, so there will be defective
contact. If there is oil or grease stuck to the
connector, wipe it off with a dry cloth or blow
it dry with compressed air and spray it with
electric contact cleaner.
a When wiping the joint portion of the connector, be careful not to apply excessive
force or deform the pins.
a If there is oil or water in the compressed
air, the contacts will become even dirtier,
so remove the oil and water from the compressed air completely before cleaning
with compressed air.

D375A-6

00-15

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

3. Removing, installing, and drying connectors


and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when disconnecting.
When disconnecting the connectors, hold
the connectors. For connectors held by a
screw, loosen the screw fully, then hold
the male and female connectors in each
hand and pull apart. For connectors
which have a lock stopper, press down
the stopper with your thumb and pull the
connectors apart.
a Never pull with one hand.
2] When removing from clips
q Both of the connector and clip have
stoppers, which are engaged with
each other when the connector is installed.

When removing a connector from a


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

3] Action to take after removing connectors


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

00-16

D375A-6

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

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

D375A-6

00-17

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

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


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

00-18

Disconnection

Connection (Example
of incomplete setting of
(a))

D375A-6

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

4) Drying wiring harness


If there is any oil or dirt on the wiring harness,
wipe it off with a dry cloth. Avoid washing it in
water or using steam. If the connector must
be washed in water, do not use high-pressure water or steam directly on the wiring
harness. If water gets directly on the
connector, do as follows.
1] Disconnect the connector and wipe off
the water with a dry cloth.
a If the connector is blown dry with compressed air, there is the risk that oil in
the air may cause defective contact,
so remove all oil and water from the
compressed air before blowing with
air.
2] Dry the inside of the connector with a dryer.
If water gets inside the connector, use a
dryer to dry the connector.
a Hot air from the dryer can be used, but
regulate the time that the hot air is
used in order not to make the connector or related parts too hot, as this will
cause deformation or damage to the
connector.

3] Carry out a continuity test on the connector.


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

D375A-6

00-19

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

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

5. Points to remember when troubleshooting electric circuits


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

00-20

D375A-6

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

Points to remember when handling hydraulic components


With the increase in pressure and precision of hydraulic components, the most common cause of failure is
dirt (foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic components, it is necessary to be particularly careful.
1. Be careful of the operating environment.
Avoid adding hydraulic oil, replacing filters, or
repairing the machine in rain or high winds, or
places where there is a lot of dust.
2. Disassembly and maintenance work in the field.
If disassembly or maintenance work is carried
out on hydraulic components in the field, there is
danger of dust entering the components. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
components should be carried out in a specially
prepared dustproof workshop, and the performance should be checked with special test
equipment.

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

4. Do not let any dirt or dust get in during refilling operations


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

D375A-6

00-21

DRAFT
Forword and general information
Handling of electric equipment and hydraulic components

5. Change hydraulic oil when the temperature is high


When hydraulic oil or other oil is warm, it flows
easily. In addition, the sludge can also be
drained out easily from the circuit together with
the oil, so it is best to change the oil when it is still
warm. When changing the oil, as much as
possible of the old hydraulic oil must be drained
out. (Drain the oil from the hydraulic tank; also
drain the oil from the filter and from the drain plug
in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil
and will shorten the life of the hydraulic oil.
6. Flushing operations
After disassembling and assembling the equipment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried out
with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.

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

00-22

D375A-6

DRAFT
Forword and general information
Handling of connectors newly used for engines

Handling of connectors newly used for engines


a Mainly, following engines are object for following connectors.
q 95E-5
q 107E-1
q 114E-3
q 125E-5
q 140E-5
q 170E-5
q 12V140E-3
Slide lock type
(FRAMATOME-3,FRAMATOME-2)
q

95170,12V140 engines
q Various pressure sensors and NE speed
sensor
Examples)
Intake air pressure sensor in intake manifold:
PIM (125,170,12V140 engines)
Oil pressure sensor: POIL (125,170,12V140
engines)
Oil pressure switch (95,107,114 engines)
Ne speed sensor of flywheel housing:
NE(95-170,12V140 engines)
Ambient
pressure
sensor:
PAMB
(125,170,12V140 engines)

Pull lock type (PACKARD-2)


q 95170,12V140 engines
q Various temperature sensors
Examples)
Intake air temperature sensor in intake manifold: TIM
Fuel temperature sensor: TFUEL
Oil temperature sensor: TOIL
Coolant temperature sensor: TWTR, etc.
Disconnect
Disconnect the connector by pulling lock (B) (on the
wiring harness side) of connector (2) outward.

Disconnect
1) Slide lock L1 to the right.
2) While pressing lock L2, pull out connector (1)
toward you.
a Even if lock L2 is pressed, connector (1)
cannot be pulled out toward you, if part A
does not float. In this case, float part A
with a small screwdriver while press lock
L2 , and then pull out connector (1) toward you.
Connect
Insert the connector straight until it "clicks".

Connect
Insert the connector straight until it "clicks".

D375A-6

00-23

DRAFT
Forword and general information
Handling of connectors newly used for engines

Push lock type (1)


q 95, 107, 114 engines
Example) Fuel pressure sensor in common rail
(BOSCH-03)

While pressing up lock (C) of the connector with


flat-head screwdriver [1], pull out connector (3) in
the direction of the arrow.

Disconnect
While pressing lock (C), pull out connector (3) in the
direction of the arrow.
q

114 engine

Connect
Insert the connector straight until it "clicks".

107 engine

Push lock type (2)


q 107, 114 engines
Example) Intake air pressure/temperature
sensor in intake manifold (SUMITOMO-04)
Disconnect
While pressing lock (D), pull out connector (4) in the
direction of the arrow.

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


screwdriver [1] since you cannot insert your fingers.
Connect
Insert the connector straight until it "clicks".

00-24

D375A-6

DRAFT
Forword and general information
Handling of connectors newly used for engines

Push lock type (3)


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

Turn-housing type (Round green connector)


q 140 engine
Example) Intake air pressure sensor in intake
manifold.
(CANNON-04): PIM etc.
Disconnect
1) Turn housing (H1) in the direction of the
arrow.
a When connector is unlocked, housing
(H1)becomes heavy to turn.
2) Pull out housing (H1) in the direction of the
arrow.
a Housing (H1) is left on the wiring harness
side.

Example) Injection pressure control valve of fuel


supply pump: PCV (SUMITOMO-2)

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

Examples) Speed sensor of fuel supply pump:G


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

Connect
Insert the connector straight until it "clicks".

D375A-6

00-25

Forword and general information


How to read electric wire code

How to read electric wire code

0 -24

In the electric circuit diagram, the material, thickness, and color of each electric wire are indicated by symbols.
The electric wire code is helpful in understanding the electric circuit diagram.
Example: AEX

0.85

---

Indicates blue, heat-resistant, low-voltage wire for automobile, having nominal No.
of 0.85
Indicates color of wire by color code.
Color codes are shown in Table 3.
Indicates size of wire by nominal No.
Size (Nominal No.) is shown in Table 2.
Indicates type of wire by symbol.
Type, symbol, and material of wire are shown in Table 1.
(Since the use of AV and AVS wires depends on size (nominal No.), their symbols
are not indicated on the diagram.)

1. Type, symbol, and material


AV and AVS are different only in thickness and outside diameter of the cover.CAVS has a circular
compressed conductor. It differs from that of AV and AVS in the outside diameter and thickness of the
cover.And AEX is similar to AV in thickness and outside diameter of the cover but different from AV and
AVS in material of the cover.
(Table 1)
Type
Low-voltage
wire for automobile
Thin-cover
low-voltage wire
for automobile
(type 1)
Thin-cover
low-voltage wire
for automobile
(type 2)
Heat-resistant
low-voltage wire
for automobile

00-26

Symbol

Material
Conductor

Annealed copper for electric


appliance

Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric


appliance

AV

AVS
Insulator

Soft polyvinyl chloride

Conductor

Annealed copper for electric


appliance

Insulator

Soft polyvinyl chloride

CAVS

Conductor
AEX
Insulator

Annealed copper for electric


appliance
Heat-resistant crosslinked
polyethylene

Using temperature

Example of use
General wiring
(nominal No. 5 and above.)

-30 to +60

General wiring
(nominal No. 3 and below.)

For mid- to small-size excavators


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

D375A-6
(04)

Forword and general information


How to read electric wire code

2. Dimensions
(Table 2)
Nominal No.

Conductor

Co
ver
D

Number of
strands/Diameter of strand
Sectional area
(mm2)

0.75f

(0.85)

1.25f

(1.25)

2f

3f

20/0.18 7/0.32 30/0.18 11/0.32 50/0.18 16/0.32 37/0.26 26/0.32 58/0.26 41/0.32 65/0.32
0.51

0.56

0.76

0.88

1.27

1.29

1.96

2.09

3.08

3.30

5.23

1.0

1.2

1.5

1.9

1.9

2.3

2.4

3.0

AVS

Standard

2.0

2.2

2.5

2.9

2.9

3.5

3.6

AV

Standard

4.6

AEX

Standard

2.0

2.2

2.7

3.0

3.1

3.8

4.6

15

20

30

50/0.45

84/0.45

41/0.80

70/0.80

7.95

13.36

20.61

35.19

42.73

54.29

63.84

84.96

109.1

d (approx.)

3.7

4.8

6.0

8.0

8.6

9.8

10.4

12.0

13.6

AVS

Standard

AV

Standard

5.5

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

AEX

Standard

5.3

7.0

8.2

10.8

11.4

13.0

13.6

16.0

17.6

Conductor

Number of
strands/Diameter of strand
Sectional area
(mm2)

Nominal No.

Conductor

Co
ver
D

(0.5)

d (approx.)

Nominal No.

Co
ver
D

0.5f

CAVS

40

50

60

85

100

85/0.80 108/0.80 127/0.80 169/0.80 217/0.80

0.5f

0.5

0.75f

0.85

1.25f

1.25

7/Circular compressed

11/Circular compressed

16/Circular compressed

0.56

0.88

1.29

(a)

0.9

1.1

1.4

Standard

1.6

1.8

2.1

Number of
strands/Diameter of strand
Sectional area
(mm2)

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

D375A-6
(04)

00-27

Forword and general information


How to read electric wire code

3. Color codes table


(Table 3)
Color Code
B
Br
BrB
BrR
BrW
BrY
Ch
Dg
G
GB
GL
Gr
GR
GW
GY
L
LB
Lg
LgB
LgR

Color of wire
Black
Brown
Brown & Black
Brown & Red
Brown & White
Brown & Yellow
Charcoal
Dark green
Green
Green & Black
Green & Blue
Gray
Green & Red
Green & White
Green & Yellow
Blue
Blue & Black
Light green
Light green & Black
Light green & Red

Color Code
LgW
LgY
LR
LW
LY
O
P
R
RB
RG
RL
RW
RY
Sb
Y
YB
YG
YL
YR
YW

Color of wire
Light green & White
Light green & Yellow
Blue & Red
Blue & White
Blue & Yellow
Orange
Pink
Red
Red & Black
Red & Green
Red & Blue
Red & White
Red & Yellow
Sky Blue
Yellow
Yellow & Black
Yellow & Green
Yellow & Blue
Yellow & Red
Yellow & White

Remarks: In a color code consisting of 2 colors, the first color is the color of the background and the second
color is the color of the marking.
Example: "GW" means that the background is Green and marking is White.
4. Types of circuits and color codes
(Table 4)
Type of wire

AEX

Charge

WG

Ground

Start

Light

RW

RB

RY

RG

RL

Instrument

YR

YB

YG

YL

YW

Gr

Signal

GW

GR

GY

GB

GL

Br

LW

LR

LY

LB

Br

BrW

BrR

BrY

BrB

Lg

LgR

LgY

LgB

LgW

Gr

Sb

Dg

Ch

Type of circuit

Others

00-28

AVS/AV/CAVS

D375A-6
(04)

DRAFT
Forword and general information
Precautions when carrying out work

Precautions when carrying out work


When carrying out removal or installation (disassembly or assembly) of units, be sure to follow the general
precautions given below when carrying out the work.
1. Precautions when carrying out removal work
q If the coolant contains antifreeze, dispose of it correctly.
q After disconnecting hoses or tubes, cover them or fit plugs to prevent dirt or dust from entering.
q When draining oil, prepare a container of adequate size to catch the oil.
q Confirm the match marks showing the installation position, and make match marks in the necessary
places before removal to prevent any mistake when assembling.
q To prevent any excessive force from being applied to the wiring, always hold the connectors when disconnecting the connectors. Do not pull the wires.
q Fit wires and hoses with tags to show their installation position to prevent any mistake when installing.
q Check the number and thickness of the shims, and keep in a safe place.
q When raising component, be sure to use lifting equipment of ample strength.
q When using forcing screws to remove any component, tighten the forcing screws uniformly in turn.
q Before removing any unit, clean the surrounding area and fit a cover to prevent any dust or dirt from
entering after removal.
a Precautions when handling piping during disassembly
Fit the following plugs into the piping after disconnecting it during disassembly operations.
1) Face seal type hoses and tubes
Nominal
number
02
03
04
05
06

Plug (nut end)

Sleeve nut (elbow end)

07376 - 70210
07376-70315
07376 - 70422
07376 - 70522
07376 - 70628

02789 - 00210
02789 - 00315
02789 - 00422
02789 - 00522
02789 - 00628

2) Split flange type hoses and tubes


Nominal
number
04
05

Flange (hose end)

Sleeve head (tube end)

Split flange

07379 - 00400
07379 - 00500

07378 - 10400
07378 - 10500

07371 - 30400
07371 - 30500

3) If the part is not under hydraulic pressure, the following corks can be used.
Nominal
number
06
08
10
12
14
16
18
20
22
24
27

D375A-6

Part No.
07049 - 00608
07049 - 00811
07049 - 01012
07049 - 01215
07049 - 01418
07049 - 01620
07049 - 01822
07049 - 02025
07049 - 02228
07049 - 02430
07049 - 02734

D
6
8
10
12
14
16
18
20
22
24
22.5

Dimensions
d
5
6.5
8.5
10
11.5
13.5
15
17
18.5
20
22.5

L
8
11
12
15
18
20
22
25
28
30
34

00-29

DRAFT
Forword and general information
Precautions when carrying out work

2. Precautions when carrying out installation work


q Tighten all bolts and nuts (sleeve nuts) to the specified torque (KES) .
q Install the hoses without twisting or interference and fix them with intermediate clamps, if there are any.
q Replace all gaskets, O-rings, cotter pins, and lock plates with new parts.
q Bend the cotter pins and lock plates securely.
q When coating with adhesive, clean the part and remove all oil and grease, then coat the threaded portion with 2 3 drops of adhesive.
q When coating with liquid gasket, clean the surface and remove all oil and grease, check that there is
no dirt or damage, then coat uniformly with liquid gasket.
q Clean all parts, and correct any damage, dents, burrs, or rust.
q Coat rotating parts and sliding parts with engine oil.
q When press fitting parts, coat the surface with molybdenum disulfide lubricant (LM-P).
q After fitting snap rings, check that the snap ring is fitted securely in the ring groove.
q When connecting wiring connectors, clean the connector to remove all oil, dirt, or water, then connect
securely.
q When using eyebolts, check that there is no deformation or deterioration, screw them in fully, and align
the direction of the hook.
q When installing split flanges, fasten uniformly in turn to prevent excessive tightening on one side.
a When operating the hydraulic cylinders for the first time after reassembling cylinders, hydraulic pumps
and other hydraulic component removed for repair, always bleed the air as follows:
1] Start the engine and run at low idle.
2] Operate the work equipment control lever to operate the hydraulic cylinder 4 5 times, stopping the
cylinder100 mm from the end of its stroke.
3] Next, operate the hydraulic cylinder 3 4 times to the end of its stroke.
4] After doing this, run the engine at normal speed.
a When using the machine for the first time after repair or long storage, follow the same procedure.
3. Precautions when completing work
1) Refilling with coolant, oil and grease
q If the coolant has been drained, close the drain valve, and add coolant to the specified level. Run
the engine to circulate the coolant through the system . Then check the coolant level again.
q If the hydraulic component has been removed and installed again, add engine oil to the specified
level. Run the engine to circulate the oil through the system. Then check the oil level again.
q If the piping or hydraulic component have been removed, always bleed the air from the system after
reassembling the parts.
a For details, see Testing and adjusting, "Bleeding air".
q Add the specified amount of grease (molybdenum disulfide grease) to the work equipment parts.
2) Checking cylinder head and manifolds for looseness
Check the cylinder head and intake and exhaust manifold for looseness.
If any part is loosened, retighten it.
q For the tightening torque, see "Disassembly and assembly" .

00-30

D375A-6

DRAFT
Forword and general information
Precautions when carrying out work

3) Checking engine piping for damage and looseness


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

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

D375A-6

00-31

DRAFT
Forword and general information
Method of disassembling and connecting push-pull type coupler

Method of disassembling and connecting push-pull type coupler


k
k

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

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

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

00-32

D375A-6

DRAFT
Forword and general information
Method of disassembling and connecting push-pull type coupler

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

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

D375A-6

00-33

DRAFT
Forword and general information
Method of disassembling and connecting push-pull type coupler

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

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

00-34

D375A-6

DRAFT
Forword and general information
Standard tightening torque table

Standard tightening torque table


1. Table of tightening torques for bolts and nuts
a Unless there are special instructions, tighten metric nuts and bolts to the torque below.
a The following table applies to the bolts in Fig. A.
Thread diameter of bolt
mm
6
8
10
12
14
16
18
20
22
24
27
30
33
36
39

Width across flats


mm
10
13
17
19
22
24
27
30
32
36
41
46
50
55
60

Tightening torque
Nm
11.8 - 14.7
27 - 34
59 - 74
98 - 123
157 - 196
245 - 309
343 - 427
490 - 608
662 - 829
824 - 1,030
1,180 - 1,470
1,520 - 1,910
1,960 - 2,450
2,450 - 3,040
2,890 - 3,630

kgm
1.2 - 1.5
2.8 - 3.5
6.0 - 7.5
10.0 - 12.5
16 -20
25 - 31.5
35 - 43.5
50 - 62
67.5 - 84.5
84 - 105
120 - 150
155 - 195
200 - 250
250 - 310
295 - 370

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


Thread diameter of bolt
mm
6
8
10
12

a Figure A

Width across flats


mm
10
12
14
17

Tightening torque
Nm
5.9 - 9.8
13.7 - 23.5
34.3 - 46.1
74.5 - 90.2

kgm
0.6 - 1.0
1.4 - 2.4
3.5 - 4.7
7.6 - 9.2

a Figure B

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

D375A-6

00-35

DRAFT
Forword and general information
Standard tightening torque table

2. Table of tightening torques for split flanged bolts


a Unless there are special instructions, tighten split flanged bolts to the torque below.
Thread diameter of bolt
mm
10
12
16

Width across flats


mm
14
17
22

Tightening torque
Nm
59 - 74
98 - 123
235 - 285

kgm
6.0 - 7.5
10.0 - 12.5
23.5 - 29.5

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


a Unless there are special instructions, tighten O-ring boss piping joints to the torque below.
Nominal No.
02
03,04
05,06
10,12
14

Thread diameter
mm
14
20
24
33
42

Width across flats


mm
Varies depending on
type of connector.

Tightening torque Nm {kgm}


Range
Target
35 63 {3.5 6.5}
44 {4.5}
84 132 {8.5 13.5}
103 {10.5}
128 186 {13.0 19.0}
157 {16.0}
363 480 {37.0 49.0}
422 {43.0}
746 1,010 {76.0 103}
883 {90.0}

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


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

00-36

Thread diameter
mm
8
10
12
14
16
18
20
24
30
33
36
42
52

Width across flats


mm
14
17
19
22
24
27
30
32
32

36

Tightening torque Nm {kgm}


Range
Target
5.88 8.82 {0.6 0.9}
7.35 {0.75}
9.8 12.74 {1.0 1.3}
11.27 {1.15}
14.7 19.6 {1.5 2.0}
17.64 {1.8}
19.6 24.5 {2.0 2.5}
22.54 {2.3}
24.5 34.3 {2.5 3.5}
29.4 {3.0}
34.3 44.1 {3.5 4.5}
39.2 {4.0}
44.1 53.9 {4.5 5.5}
49.0 {5.0}
58.8 78.4 {6.0 8.0}
68.6 {7.0}
93.1 122.5 { 9.5 12.5}
107.8 {11.0}
107.8 147.0 {11.0 15.0}
127.4 {13.0}
127.4 176.4 {13.0 18.0}
151.9 {15.5}
181.3 240.1 {18.5 24.5}
210.7 {21.5}
274.4 367.5 {28.0 37.5}
323.4 {33.0}

D375A-6

DRAFT
Forword and general information
Standard tightening torque table

5. Table of tightening torques for hoses (taper seal type and face seal type)
a Unless there are special instructions, tighten the hoses (taper seal type and face seal type) to the
torque below.
a Apply the following torque when the threads are coated (wet) with engine oil.
Tightening torque Nm {kgm}
Nominal
No. of
hose

Width
across
flats

02

19

03
04
05
06
(10)
(12)
(14)

22
24
27
32
36
41
46
55

Taper seal

Range

Target

Thread size
(mm)

34 54 {3.5 5.5}
34 63 {3.5 6.5}
54 93 {5.5 9.5}
59 98 {6.0 10.0}
84 132 {8.5 13.5}
128 186 {13.0 19.0}
177 245 {18.0 25.0}
177 245 {18.0 25.0}
197 294 {20.0 30.0}
246 343 {25.0 35.0}

44 {4.5}
44 {4.5}
74 {7.5}
78 {8.0}
103 {10.5}
157 {16.0}
216 {22.0}
216 {22.0}
245 {25.0}
294 {30.0}

14
18
22
24
30
33
36
42

Face seal
Nominal No.
Thread diameNumber of
ter (mm) (Refthreads, type
erence)
of thread
9/16 - 18UNF
14.3
11/16 - 16UN
17.5
13/16 - 16UN
20.6
1 - 14UNS
25.4
1 - 3/16 - 12UN
30.2
-

6. Table of tightening torques for face seal joints


a Tighten the face seal joints (sleeve nut type) made of plated steel pipes for low pressure service to be
used for engines etc. to the torque shown in the following table.
a Apply the following torque to the face seal joint while their threaded parts are coated with engine oil
(wetted).
Outer
diameter
of pipe
(mm)
8
10
12
15 (16)
22 (20)

Width
across
flats
(mm)
19
22
24 (27)
30 (32)
36

Tightening torque Nm {kgm}


Range

Target

14 16 {1.4 1.6}
24 27 {2.4 2.7}
43 47 {4.4 4.8}
60 68 {6.1 6.8}
90 95 {9.2 9.7}

15 {1.5}
25.5 {2.6}
45 {4.6}
64 {6.5}
92.5 {9.4}

Face seal
Nominal No. Number
Thread diameter (mm)
of threads, type of
(Reference)
thread
9/16 18UN
14.3
11/16 16UN
17.5
13/16 16UN
20.6
1 14UN
25.4
1 3/16 12UN
30.2

Reference: The face seal joints of the dimensions in ( ) are slso used, depending on the specification.
7. Table of tightening torques for 102, 107 and 114 engine series (Bolts and nuts)
a Unless there are special instructions, tighten the metric bolts and nuts of the 102, 107 and 114 engine
series to the torque below.
Tightening torque
Bolts and nuts

Thread size
mm
6
8
10
12
14

D375A-6

Nm
10 2
24 4
43 6
77 12
-

kgm
1.02 0.20
2.45 0.41
4.38 0.61
7.85 1.22
-

00-37

DRAFT
Forword and general information
Standard tightening torque table

8. Table of tightening torques for 102, 107 and 114 engine series (Eye joints)
a Unless there are special instructions, tighten the metric eye joints of the 102, 107 and 114 engine series to the torque below.
Thread size
mm
6
8
10
12
14

Tightening torque
Nm
82
10 2
12 2
24 4
36 5

kgm
0.81 0.20
1.02 0.20
1.22 0.20
2.45 0.41
3.67 0.51

9. Table of tightening torques for 102, 107 and 114 engine series (Taper screws)
a Unless there are special instructions, tighten the taper screws (unit: inch) of the 102, 107 and 114 engine series to the torque below.
Material
Thread size (inch)
1/16
1/8
1/4
3/8
1/2
3/4

00-38

Tightening torque
In cast iron or steel
In aluminum
Nm
kgm
Nm
kgm
15 2
1.53 0.20
51
0.51 0.10
20 2
2.04 0.20
15 2
1.53 0.20
25 3
2.55 0.31
20 2
2.04 0.20
35 4
3.57 0.41
25 3
2.55 0.31
55 6
5.61 0.61
35 4
3.57 0.41
75 8
7.65 0.82
45 5
4.59 0.51

D375A-6

DRAFT
Forword and general information
List of Abbreviation

List of Abbreviation
q

This list of abbreviations is taken from the abbreviations used in the text of the shop manual for
parts, components, and functions whose meaning is not immediately clear. The spelling is given
in full with an outline of the meaning.
Abbreviations that are used in general society
may not be included.

q
q

Special abbreviations that appear infrequently


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

List of abbreviations used in the shop manual


Abbreviation

Full Spelling

Purpose of use
(major applicable machine(*), or
component/
system)

A.B.S.

Travel and brake


Anti-skid Brake System
(HD, HM)

A.I.S.S.

Automatic Idling Setting


Engine
System

A.J.S.S.

Advanced Joystick
Steering System

Steering
(WA)

A.R.A.C.

Automatic Retarder
Accelerator Control

Travel and brake


(HD, HM)

A.R.S.C.

Automatic Retarder
Speed Control

Travel and brake


(HD, HM)

A.S.R.
ATT.

Automatic Spin Regula- Travel and brake


tor
(HD, HM)
Attachment

Work equipment

B.C.V.

Breake Cooling oil con- Brake


trol Valve
(HD)

C.A.N.

Controller Area Network

Communication and electronic


control

Closed-center Load
Sensing System

Hydraulic

C.R.I.

Common Rail Injection

Engine

E.C.M.

Electronic Control ModElectronic control system


ule

C.L.S.S.

E.C.M.V.

Electronic Control Mod- Transmission


ulation Valve
(WA, D, HD, etc.)

Electronically ConTravel
E.C.S.S. trolled Suspension Sys(WA)
tem

D375A-6

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

00-39

DRAFT
Forword and general information
List of Abbreviation

Abbreviation

Full Spelling

Purpose of use
(major applicable machine(*), or
component/
system)

E.C.U.

Electronic Control Unit

E.G.R.

Exhaust Gas RecirculaEngine


tion

E.M.M.S.

Electronic control system

Equipment ManageMachine monitor


ment Monitoring System

E.P.C.

Electromagnetic ProporHydraulic
tional Control

F-N-R

Forward-Neutral-Reverse

G.P.S.

Global Positioning Sys- Communication


tem
(KOMTRAX, VHMS)

H.S.S.

Hydrostatic Steering
System

Steering
(D)

H.S.T.

Hydro Static Transmission

Transmission
(WA, D: Small size)

I.M.A.

Inlet Metering Actruator Engine

I.M.V.

Inlet Metering Valve

Engine

L.C.D.

Liquid Crystal Display

Machine monitor

L.E.D.

Light Emitting Diode

Electronic parts

Load Sensing

Hydraulic

Multimedia Messaging
Service

Communication

N.C.

Normally Closed

Electronic and hydraulic

N.O.

Normally Open

Electronic and hydraulic

O.L.S.S.

Open-center Load
Sensing System

Hydraulic

P.C.

Pressure Control

Hydraulic

L.S.

M.M.S.

00-40

Operation

Explanation
Electronic control device that uses the signals
from the sensors on the machine to indicate
to the actuators the optimum actuation. (same
as ECM)
Functions to recirculate part of exhaust gas to
combustion chamber in order to reduce combustion temperature, controls emission of
Nox.
System that allows data (filter, oil replacement
interval, abnormalities on machine, failure
code, and failure history) from each sensor on
the machine to be checked on monitor.
Control system that moves an actuator in proportion to the amperage of an electric current
passing through the solenoid.
Position of the gear shift lever or switch.
System that is used to determine the current
location on the Earth of a ship, car, machine,
etc. by receiving the radio wave signals transmitted from the navigation satellites.
Steering function that uses a combination of
hydraulic motor and bevel shaft to control difference in travel speed of left and right tracks
to turn machine without using steering clutch.
Hydraulic transmission system that uses a
combination of hydraulic pump and hydraulic
motor to shift gear steplessly without using
gears.
Valve installed at inlet port of pump to adjust
fuel intake amount in order to control fuel discharge amount of supply pump. Same as
IMV.
Valve installed at inlet port of pump to adjust
fuel intake amount in order to control fuel discharge amount of supply pump. Described as
IMV (IMA).
Image display device made up of a large
number of pixels filled with liquid crystal.
Semiconductor element that emits light when
the voltage is applied in forward direction,
positive voltage to anode and negative voltage to cathode.
Function that senses differential pressure of
pump and controls discharge amount according to load.
Service that allows transmission and reception of short messages consisting of characters or voice or images between cell phones.
Device actuated to open electric or hydraulic
circuits that are normally closed if not actuated.
Device actuated to close electric or hydraulic
circuits that are normally open if not actuated.
Hydraulic system that can operate multiple
actuators at the same time, regardless of the
load.
Controlling the oil pressure.

D375A-6

DRAFT
Forword and general information
List of Abbreviation

Abbreviation

Full Spelling

Palm Command ConP.C.C.S.


trol System

Steering
(D)

P.C.V.

Pump Control Valve

Engine

P.P.C.

Proportional Pressure
Control

Hydraulic

P.P.M.

Piston Pump and Motor

Hydraulic
(PC, D, etc.)

P.T.O.

Power Take Off

Power train

P.T.P.

Power Tilt and power


Pitch dozer

Work equipment
(D)

S.I.

Le System International
Unit
d' Unites

SOL.

Solenoid

Electronic

T.W.V.

Two Way Valve

Hydraulic and electronic

V.H.M.S.

*:

Purpose of use
(major applicable machine(*), or
component/
system)

Vehicle Health Monitor- Monitoring and communication


ing System
(PC, WA, D, HD: Large size)

Explanation
System in which a controller instantly analyses data from each lever, pedal, and dial, and
carries out optimum electronic control of the
engine and HST.
Valve installed at inlet port of pump to adjust
fuel intake amount in order to control fuel discharge amount of supply pump.
Control system that moves an actuator in proportion to the oil pressure.
Piston pump and motor.
A device to take off power of the engine in
order to drive a hydraulic pump, an air compressor, etc.
Function that carries out hydraulic control of
the tilt and pitch of the bulldozer blade.
International System of Units (abbreviated SI
from the French Le Systeme Internationale
d'Unites) is the modern form of the metric system, and is the world's most widely used system of measurement.
There're seven base units: meter (m), kilogram (kg), second (s), ampere (A), kelvin (K),
candela (cd), and mole (mol).
The derived units include Pascal (Pa), Newton (N), etc.
Solenoid is a loop of wire. However, as a matter of fact in engineering, it refers to an actuator consists of a solenoid and an iron core that
is moved by the magnetic force when the
solenoid is energized. The word solenoid also
often refers to a solenoid valve.
Solenoid valve that switches over direction of
flow.
Communications system that transmits
machine data, such as the present position of
the machine, daily or aggregate hours of
operation, fuel consumption, radiator water
temperature, oil or filter replacement interval,
to make it possible to collect and check this
data from a distant place (Developed for use
on large machines used in mines).

Code for machine family


HD: Dump truck
HM: Articulate dump truck
WA: Wheel loader
D: Bulldozer
PC: Hydraulic excavator

D375A-6

00-41

DRAFT
Forword and general information
List of Abbreviation

List of abbreviations used in the circuit drawings


Abbreviation

Full Spelling

A/C

Air Conditioner

A/D

Analogue-to-Digital

A/M

Air Mix damper

ACC

Accessory

ADD

Additional

AUX

Auxiliary

BR

Battery Relay

CW

Clockwise

CCW

Counter Clockwise

ECU

Electronic Control Unit

ECM

Electronic Control Module

ENG

Engine

EXGND

External Ground

F.G.

Frame Ground

GND

Ground

IMA

Inlet Metering Actruator

NC

No Connection

S/T
Steering
STRG
SIG

Signal

SOL

Solenoid

STD

Standard

OPT
Option
OP

00-42

SW

Switch

T/C

Torque Converter

T/M

Transmission

D375A-6

DRAFT
Forword and general information
Conversion table

Conversion table
Method of using the conversion table
The conversion table in this section is provided to enable simple conversion of figures. For details of the method of using the conversion table, see the example given below.
Example: Method of using the conversion table to convert from millimeters to inches
1. Convert 55 mm into inches.
1) Locate the number 50 in the vertical column at the left side, take this as (A), and then draw a horizontal
line from (A).
2) Locate the number 5 in the row across the top, take this as (B), then draw a perpendicular line down
from (B).
3) Take the point where the 2 lines cross as (C). This point (C) gives the value when converting from millimeters to inches. Therefore, 55 mm = 2.165 inches.
2. Convert 550 mm into inches.
1) The number 550 does not appear in the table, so divide it by 10 (move the decimal point one place to
the left) to convert it to 55 mm.
2) Carry out the same procedure as above to convert 55 mm to 2.165 inches.
3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point
one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters to inches

(A)

D375A-6

(B)

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.017
2.441
2.835
3.228
3.622

2.087
2.480
2.847
3.268
3.661

2.126
2.520
2.913
3.307
3.701

5
0.197
0.591
0.984
1.378
1.772
(C)
2.165
2.559
2.953
3.346
3.740

6
0.236
0.630
1.024
1.417
1.811

7
0.276
0.669
1.063
1.457
1.850

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929
2.283
2.677
3.071
3.465
3.858

2.323
2.717
3.110
3.504
3.898

00-43

DRAFT
Forword and general information
Conversion table

Millimeters to inches

0
10
20
30
40

0
0
0.394
0.787
1.181
1.575

1
0.039
0.433
0.827
1.220
1.614

2
0.079
0.472
0.866
1.260
1.654

3
0.118
0.512
0.906
1.299
1.693

4
0.157
0.551
0.945
1.339
1.732

5
0.197
0.591
0.984
1.378
1.772

5
0.236
0.630
1.024
1.417
1.811

7
0.276
0.669
1.063
1.457
1.850

1 mm = 0.03937 in
8
9
0.315
0.354
0.709
0.748
1.102
1.142
1.496
1.536
1.890
1.929

50
60
70
80
90

1.969
2.362
2.756
3.150
3.543

2.008
2.402
2.795
3.189
3.583

2.017
2.441
2.835
3.228
3.622

2.087
2.480
2.847
3.268
3.661

2.126
2.520
2.913
3.307
3.701

2.165
2.559
2.953
3.346
3.740

2.205
2.598
2.992
3.386
3.780

2.244
2.638
3.032
3.425
3.819

2.283
2.677
3.071
3.465
3.858

0
10
20
30
40

0
0
22.05
44.09
66.14
88.18

1
2.20
24.25
46.30
68.34
90.39

2
4.41
26.46
48.50
70.55
92.59

3
6.61
28.66
50.71
72.75
94.80

4
8.82
30.86
51.91
74.96
97.00

5
11.02
33.07
55.12
77.16
99.21

6
13.23
35.27
57.32
79.37
101.41

7
15.43
37.48
59.53
81.57
103.62

1 kg = 2.2046 lb
8
9
17.64
19.84
39.68
41.89
61.73
63.93
83.78
85.98
105.82
108.03

50
60
70
80
90

110.23
132.28
154.32
176.37
198.42

112.44
134.48
156.53
178.57
200.62

114.64
136.69
158.73
180.78
202.83

116.85
138.89
160.94
182.98
205.03

119.05
141.10
163.14
185.19
207.24

121.25
143.30
165.35
187.39
209.44

123.46
145.51
167.55
189.60
211.64

125.66
147.71
169.76
191.80
213.85

127.87
149.91
171.96
194.01
216.05

0
10
20
30
40

0
0
2.642
5.283
7.925
10.567

1
0.264
2.906
5.548
8.189
10.831

2
0.528
3.170
5.812
8.454
11.095

3
0.793
3.434
6.076
8.718
11.359

4
1.057
3.698
6.340
8.982
11.624

5
1.321
3.963
6.604
9.246
11.888

6
1.585
4.227
6.869
9.510
12.152

7
1.849
4.491
7.133
9.774
12.416

1l= 0.2642 U.S.Gal


8
9
2.113
2.378
4.755
5.019
7.397
7.661
10.039
10.303
12.680
12.944

50
60
70
80
90

13.209
15.850
18.492
21.134
23.775

13.473
16.115
18.756
21.398
24.040

13.737
16.379
19.020
21.662
24.304

14.001
16.643
19.285
21.926
24.568

14.265
16.907
19.549
22.190
24.832

14.529
17.171
19.813
22.455
25.096

14.795
17.435
20.077
22.719
25.361

15.058
17.700
20.341
22.983
25.625

15.322
17.964
20.605
23.247
25.889

2.323
2.717
3.110
3.504
3.898

Kilogram to pound

130.07
152.12
174.17
196.21
218.26

Liters to U.S. Gallons

00-44

15.586
18.228
20.870
23.511
26.153

D375A-6

DRAFT
Forword and general information
Conversion table

Liters to U.K. Gallons


1l = 0.21997 U.K.Gal
8
9
1.760
1.980
3.950
4.179
6.159
6.379
8.359
8.579
10.559
10.778

0
10
20
30
40

0
0
2.200
4.399
6.599
8.799

1
0.220
2.420
4.619
6.819
9.019

2
0.440
2.640
4.839
7.039
9.239

3
0.660
2.860
5.059
7.259
9.459

4
0.880
3.080
5.279
7.479
9.679

5
1.100
3.300
5.499
7.699
9.899

6
1.320
3.520
5.719
7.919
10.119

7
1.540
3.740
5.939
8.139
10.339

50
60
70
80
90

10.998
13.198
15.398
17.598
19.797

11.281
13.418
15.618
17.818
20.017

11.438
13.638
15.838
18.037
20.237

11.658
13.858
16.058
18.257
20.457

11.878
14.078
16.278
18.477
20.677

12.098
14.298
16.498
18.697
20.897

12.318
14.518
16.718
18.917
21.117

12.528
14.738
16.938
19.137
21.337

0
10
20
30
40

0
0
72.3
144.7
217.0
289.3

1
7.2
79.6
151.9
224.2
296.6

2
14.5
86.8
159.1
231.5
303.8

3
21.7
94.0
166.4
238.7
311.0

4
28.9
101.3
173.6
245.9
318.3

5
36.2
108.5
180.8
253.2
325.5

6
43.4
115.7
188.1
260.4
332.7

7
50.6
123.0
195.3
267.6
340.0

1 kgm = 7.233 ft.lb


8
9
57.9
65.1
130.2
137.4
202.5
209.8
274.9
282.1
347.2
354.4

50
60
70
80
90

361.7
434.0
506.3
578.6
651.0

368.9
441.2
513.5
585.9
658.2

376.1
448.5
520.8
593.1
665.4

383.4
455.7
528.0
600.3
672.7

390.6
462.9
535.2
607.6
679.9

397.8
470.2
542.5
614.8
687.1

405.1
477.4
549.7
622.0
694.4

412.3
484.6
556.9
629.3
701.6

419.5
491.8
564.2
636.5
708.8

426.8
499.1
571.4
643.7
716.1

100
110
120
130
140

723.3
795.6
868.0
940.3
1012.6

730.5
802.9
875.2
947.5
1019.9

737.8
810.1
882.4
954.8
1027.1

745.0
817.3
889.7
962.0
1034.3

752.2
824.6
896.9
969.2
1041.5

759.5
831.8
904.1
976.5
1048.8

766.7
839.0
911.4
983.7
1056.0

773.9
846.3
918.6
990.9
1063.2

781.2
853.5
925.8
998.2
1070.5

788.4
860.7
933.1
1005.4
1077.7

150
160
170
180
190

1084.9
1157.3
1129.6
1301.9
1374.3

1092.2
1164.5
1236.8
1309.2
1381.5

1099.4
1171.7
1244.1
1316.4
1388.7

1106.6
1179.0
1251.3
1323.6
1396.0

1113.9
1186.2
1258.5
1330.9
1403.2

1121.1
1193.4
1265.8
1338.1
1410.4

1128.3
1200.7
1273.0
1345.3
1417.7

1135.6
1207.9
1280.1
1352.6
1424.9

1142.8
1215.1
1287.5
1359.8
1432.1

1150.0
1222.4
1294.7
1367.0
1439.4

12.758
14.958
17.158
19.357
21.557

12.978
15.178
17.378
19.577
21.777

kgm to ft.lb

D375A-6

00-45

DRAFT
Forword and general information
Conversion table

kg/cm2 to lb/in2

0
10
20
30
40

0
0
142.2
284.5
426.7
568.9

1
14.2
156.5
298.7
440.9
583.2

2
28.4
170.7
312.9
455.1
597.4

3
42.7
184.9
327.1
469.4
611.6

4
56.9
199.1
341.4
483.6
625.8

5
71.1
213.4
355.6
497.8
640.1

6
85.3
227.6
369.8
512.0
654.3

1 kg/cm2 = 14.2233 lb/in2


7
8
9
99.6
113.8
128.0
241.8
256.0
270.2
384.0
398.3
412.5
526.3
540.5
554.7
668.5
682.7
696.9

50
60
70
80
90

711.2
853.4
995.6
1,138
1,280

725.4
867.6
1,010
1,152
1,294

739.6
881.8
1,024
1,166
1,309

753.8
896.1
1,038
1,181
1,323

768.1
910.3
1,053
1,195
1,337

782.3
924.5
1,067
1,209
1,351

796.5
938.7
1,081
1,223
1,365

810.7
953.0
1,095
1,237
1,380

825.0
967.2
1,109
1,252
1,394

839.2
981.4
1,124
1,266
1,408

100
110
120
130
140

1,422
1,565
1,707
1,849
1,991

1,437
1,579
1,721
1,863
2,005

1,451
1,593
1,735
1,877
2,020

1,465
1,607
1,749
1,892
2,034

1,479
1,621
1,764
1,906
2,048

1,493
1,636
1,778
1,920
2,062

1,508
1,650
1,792
1,934
2,077

1,522
1,664
1,806
1,949
2,091

1,536
1,678
1,821
1,963
2,105

1,550
1,693
1,835
1,977
2,119

150
160
170
180
190

2,134
2,276
2,418
2,560
2,702

2,148
2,290
2,432
2,574
2,717

2,162
2,304
2,446
2,589
2,731

2,176
2,318
2,460
2,603
2,745

2,190
2,333
2,475
2,617
2,759

2,205
2,347
2,489
2,631
2,773

2,219
2,361
2,503
2,646
2,788

2,233
2,375
2,518
2,660
2,802

2,247
2,389
2,532
2,674
2,816

2,262
2,404
2,546
2,688
2,830

200
210
220
230
240

2,845
2,987
3,129
3,271
3,414

2,859
3,001
3,143
3,286
3,428

2,873
3,015
3,158
3,300
3,442

2,887
3,030
3,172
3,314
3,456

2,901
3,044
3,186
3,328
3,470

2,916
3,058
3,200
3,343
3,485

2,930
3,072
3,214
3,357
3,499

2,944
3,086
3,229
3,371
3,513

2,958
3,101
3,243
3,385
3,527

2,973
3,115
3,257
3,399
3,542

00-46

D375A-6

DRAFT
Forword and general information
Conversion table

Temperature
Fahrenheit-Centigrade conversion: A simple way to convert a Fahrenheit temperature reading into a Centigrade temperature reading or vice versa is to enter the accompanying table in the center (boldface column)
of figures. These figures refer to the temperature in either Fahrenheit or Centigrade degrees.
When convert from Fahrenheit to Centigrade degrees, consider the center column to be a table of Fahrenheit
temperatures and read the corresponding Centigrade temperature in the column at the left.
When convert from Centigrade to Fahrenheit degrees, consider the center column to be a table of Centigrade
values, and read the corresponding Fahrenheit temperature on the right.
C
40.4
37.2
34.4
31.7
28.9

F
114.8
116.6
118.4
120.2
122.0

C
27.2
27.8
28.3
28.9
29.4

1C = 33.8F
F
81
177.8
82
179.6
83
181.4
84
183.2
85
185.0

54
55

123.8
125.6
127.4
129.2
131.0

30.0
30.6
31.1
31.7
32.2

86
87
88
89
90

186.8
188.6
190.4
192.2
194.0

13.3
13.9
14.4
15.0
15.6

56
57
58
59
60

132.8
134.6
136.4
138.2
140.0

32.8
33.3
33.9
34.4
35.0

91
92
93
94
95

195.8
197.6
199.4
201.2
203.0

78.8
80.6
82.4
84.2
86.0

16.1
16.7
17.2
17.8
18.3

61
62
63
64
65

141.8
143.6
145.4
147.2
149.0

35.6
36.1
36.7
37.2
37.8

96
97
98
99
100

204.8
206.6
208.4
210.2
212.0

31
32
33
34
35

87.8
89.6
91.4
93.2
95.0

18.9
19.4
20.0
20.6
21.1

66
68
69
69
70

150.8
152.6
154.4
156.2
158.0

40.6
43.3
46.1
48.9
51.7

105
110
115
120
125

221.0
230.0
239.0
248.0
257.0

2.2
2.8
3.3
3.9
4.4

36
37
38
39
40

96.8
98.6
100.4
102.2
104.0

21.7
22.2
22.8
23.3
23.9

71
72
73
74
75

159.8
161.6
163.4
165.2
167.0

54.4
57.2
60.0
62.7
65.6

130
135
140
145
150

266.0
275.0
284.0
293.0
302.0

5.0
5.6
6.1
6.7
7.2

41
42
43
44
45

105.8
107.6
109.4
111.2
113.0

24.4
25.0
25.6
26.1
26.7

76
77
78
79
80

168.8
170.6
172.4
174.2
176.0

68.3
71.1
73.9
76.7
79.4

155
160
165
170
175

311.0
320.0
329.0
338.0
347.0

40
35
30
25
20

F
40.0
31.0
22.0
13.0
4.0

C
11.7
11.1
10.6
10.0
9.4

11
12
13
14
15

F
51.8
53.6
55.4
57.2
59.0

C
7.8
8.3
8.9
9.4
10.0

28.3
27.8
27.2
26.7
26.1

19
18
17
16
15

2.2
0.4
1.4
3.2
5.0

8.9
8.3
7.8
7.2
6.7

16
47
18
19
20

60.8
62.6
64.4
66.2
68.0

10.6
11.1
11.7
12.2
12.8

51
52

25.6
25.0
24.4
23.9
23.3

14
13
12
11
10

6.8
8.6
10.4
12.2
14.0

6.1
5.6
5.0
4.4
3.9

21
22
23
24
25

69.8
71.6
73.4
75.2
77.0

22.8
22.2
21.7
21.1
20.6

9
8
7
6
5

15.8
17.6
19.4
21.2
23.0

3.3
2.8
2.2
1.7
1.1

26
27
28
29
30

20.0
19.4
18.9
18.3
17.8

4
3
2
1
0

24.8
26.6
28.4
30.2
32.0

0.6
0
0.6
1.1
1.7

17.2
16.7
16.1
15.6
15.0

1
2
3
4
5

33.8
35.6
37.4
39.2
41.0

14.4
13.9
13.3
12.8
12.2

6
7
8
9
10

42.8
44.6
46.4
48.2
50.0

D375A-6

46
47
48
49
50

00-47

DRAFT
Forword and general information
Conversion table

00-48

D375A-6

DRAFT
D375A-6
SEN05011-00

Bulldozer
Shop Manual

D375A-6

Machine model
D375A-6

Serial number
60001 and up

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

D375A-6

01-1

DRAFT
Contents

Contents
01 Specification
Specification and technical data
Specification drawing ...................................................................................................................................
Specifications...............................................................................................................................................
Weight table .................................................................................................................................................
Table of fuel, coolant and lubricants ............................................................................................................

01-2

01 3
01 4
01 9
01 - 11

D375A-6

DRAFT
Specification and technical data
Specification drawing

Specification and technical data


Specification drawing

Item
A
B
C

Overall
length
Overall
height
(with ROPS)
Overall width

D375A-6

Unit

Sem i - U tilt dozer +


Giant ripper

Full - U tilt dozer +


Giant ripper

Semi - U tilt dozer + Full - U tilt dozer +


Multi - shank ripper Multi - shank ripper

mm

10,485

10,845

10,195

10,555

mm

4,265
(4,285)

4,265
(4,285)

4,265
(4,285)

4,265
(4,285)

mm

4,774

5,215

4,774

5,215

01-3

DRAFT
Specification and technical data
Specifications

Weight

Specifications
Machine model

D375A-6

Serial number

60001 and up

Machine weight
q Bare tractor
q Ditto with semi - U dozer
q Ditto with variable multi - shank ripper
q Ditto with ROPS cab + Air conditioner + Seat
belt + Perforated side cover + SSC
q
q

53,200
64,160
70,960
72,230
kg
65,665

Bare tractor with full - U dozer


Ditto with variable giant ripper

71,865
73,135

m
deg.
deg.

4.2
30
35

Forward

1st
2nd
3rd (low speed)
3rd

km/h

0 3.5
0 6.8
0 8.0
0 11.8

Reverse

1st
2nd
3rd (low speed)
3rd

km/h

0 4.6
0 8.9
0 9.7
0 15.8

Forward

1st
2nd
3rd

km/h

0 3.5
0 6.8
0 11.8

Reverse

Transmission speed ranges (man- Transmission speed ranges (autoual gear shift mode)
matic gear shift mode)

Performance

Ditto with ROPS cab + Air conditioner + Seat


belt + Perforated side cover + SSC
Min. turning radius
Gradeability
Stability (front, rear, left, right)

1st
2nd
3rd

km/h

0 4.6
0 8.7
0 14.7

Ground pressure (610 shoe)

q
q

01-4

q
q
q

q
q

Bare tractor
With semi - U dozer
With full - U dozer
With semi - U dozer and variable
multi-shank ripper

107.87 {1.10}
129.45 {1.32}
132.39 {1.35}
143.18 {1.46}

Ditto with ROPS cab + Air conditioner


+ Seat belt + Perforated side cover +
kPa {kg/cm2}
SSC belt, perforated side cover, and
SSC
With full-U dozer and variable giant
ripper
Ditto with ROPS cab + Air conditioner
+ Seat belt + Perforated side cover +
SSC

146.12 {1.49}

145.14 {1.48}
148.08 {1.51}

D375A-6

Dimensions

Overall height Overall width

Dimensions

Overall length

Specification dimension drawings


Specifications

Machine model

D375A-6

Serial number

60001 and up

Bare tractor
With semi-U dozer
With full-U dozer
With semi-U dozer + variable multi-shank ripper
With full-U dozer + variable multi-shank ripper

mm

5,905
7,780
8,140
10,195
10,845

Bare tractor
With semi-U dozer
With full-U dozer

mm

3,240
4,695
5,140

To tip of exhaust pipe


To top of air intake duct

mm

4,265
3,525

mm

2,500
3,980
610
662

Track gauge
Length of track on ground
Track shoe width
Maximum ground clearance
Model
Type

Performance

Engine

No. of cylinders bore x stroke


Piston displacement
Flywheel horsepower (ISO 9249)
Max. torque
Max. high idle speed
Min. low idle speed
Min. fuel consumption ratio

Starting motor
Alternator
Battery
Radiator core type
Torque converter

Power train

Transmission

Bevel gear shaft


Steering clutch

Steering brake

Final drive

D375A-6
(04)

mm
l {cc}
kW {HP} /rpm
Nm {kgm} / rpm
rpm
rpm
g/kWh
{g/HPh}

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

01-5

DRAFT

Undercarriage

Specification and technical data


Specifications

Machine model

D375A-6

Serial number

60001 and up
Rigid, equalizer bar
2 each side
8 each side
Assembly type, single grouser, 41 each side,
pitch: 280.0 mm , width: 610 mm

Suspension
Carrier roller
Track roller
Track shoe

Power train + Lubricating oil pump (tandem)

Gear type (BAL180 + 112)

Scavenging pump (tandem)

Gear type (BAR63 + 277)

Cooling fan pump

MPa {kg/cm2}
l/min / rpm

Cooling fan motor

MPa {kg/cm2}

Variable swash plate type (LPV90 + 30)


Max. delivery pressure: 18.1 {184}
Theoretical delivery: 231/1,926
Fixed swash plate type (LMF 150)
Max. allowable working pressure: 18.1 {184}

MPa {kg/cm2}

27.5 {280}

l/min

Variable swash plate type (HPV190)


366

Hydraulic
pump

Type
Delivery (engine speed at 1,800rpm)

Control valve

Machines with single tilt blade and


variable ripper
q For ripper tilt cylinder
q For ripper lift cylinder
q For blade tilt cylinder
q For blade lift cylinder
q For blade lift cylinder
Machines with dual tilt blade and variable ripper
q For ripper tilt cylinder
q For ripper lift cylinder
q For blade tilt L.H cylinder
q For blade tilt R.H cylinder
q For blade lift cylinder
q For blade lift cylinder

01-6

1 + 1 + 1 + 2 spool type, hydraulic assisted, PPC


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

Dimensions of blade lift


cylinder

double acting piston

Cylinder bore
Piston rod outside diameter
Piston stroke
Max. between pins distance
Min. between pins distance

Dimensions of blade tilt


cylinder

Type

Hydraulic cylinder

Work equipment hydraulic system

Max. pressure

Cylinder bore
Piston rod outside diameter
Piston stroke
Max. between pins distance
Min. between pins distance

mm

140
90
1,721
2,495
774

mm

200
110
240
1,703
1,463

D375A-6

Dimensions of ripper tilt cylinder Dimensions of ripper lift cylinder

Hydraulic cylinder

Work equipment hydraulic system

Dimensions of blade dual


tilt cylinder

Specification dimension drawings


Specifications

Machine model

D375A-6

Serial number

60001 and up

Cylinder bore

200

Piston rod outside diameter


(both right and left)

110

Piston stroke (both right and left)

mm

Max. distance between pins


(both right and left)
Min. distance between pins
(both right and left)

Cylinder bore
Piston rod outside diameter
Piston stroke
Max. between pins distance
Min. between pins distance

Cylinder bore
Piston rod outside diameter
Piston stroke
Max. between pins distance
Min. between pins distance

1,675
1,490

mm

200
110
495
1,855
1,360

mm

180
110
550
1,800
1,250

Hydraulic tank

Box type (control valve externally installed)


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

Type

Single tilt
Left: Brace type
Right: Tilt cylinder type
Dual tilt
Left: Tilt cylinder type (for single tilt/dual tilt pitch)
Right: Tilt cylinder type (for dual tilt pitch)

Performance

Max. lift above ground


Max. drop below ground
Max. adjustment tilt
Hydraulic oil tilt (single)
Blade cutting angle adjustment
Blade capacity

mm
mm
mm
mm
deg.
m3

Dimensions

Semi-U dozer

Work equipment

Blade supporting method

D375A-6
(04)

185

Blade width
Blade height
Blade cutting angle

mm
mm
deg.

1,660
715
990
770
5
24.0 <SAE18.5>
4,774
2,265 (with spill guard: 2,525)
55

01-7

DRAFT
Specification and technical data
Specifications

Machine model

D375A-6

01-8

Performance

Max. lift above ground


Max.drop below ground
Max. adjustment tilt
Hydraulic oil tilt (single)
Blade cutting angle adjustment
Blade capacity

1,660
715
1,080
840
5
26.3 <SAE22.0>

Dimensions

Blade width
Blade height
Blade cutting angle

mm
mm
deg.

5,215
2,265 (with spill guard: 2,525)
55

Performance

Max. hydraulic oil tilt


Max. pitch angle
Blade cutting angle

mm
deg.
deg.

1,185
Forward 4.7 / Backward 5.2
55

Dimensions

60001 and up
mm
mm
mm
mm
deg.
m3

Max. hydraulic oil tilt


Max. pitch angle
Blade cutting angle

mm
deg.
deg.

1,295
Forward 4.7 / Backward 5.2
55

Max. digging depth


Max. lift above ground
Point digging angle

mm
mm
deg.

1,140
1,135
45 (Stepless adjustment between 31.4 54.7)

mm
No. of holes

2,910
2

mm
mm
deg.

1,485
1,100
45 (Stepless adjustment between 31.6 55.0)

mm
No. of holes

1,600
3

Dimensions Performance Dimensions Performance

Full - U dozer + Pitch Semi - U dozer + Pitch


Giant ripper

Multi - shank ripper

Work equipment

Full - U dozer

Serial number

Max. beam width


Shank positions

Max. digging depth


Max. lift above ground
Point digging angle

Max. beam width


Shank positions

D375A-6

Specification dimension drawings


Weight table

Weight table
k

01-9

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

D375A-6

Serial number

60001 and up

Engine, damper assembly


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

Track group assembly (each side)


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

Track shoe assembly (610 mm )


Pivot shaft
Equalizer bar assembly
Hydraulic tank assembly (excluding oil )
Control valve (for single tilt)
Control valve (for dual tilt)

D375A-6
(06)

3,320
3,065
185
70
465
92
580 (1,600)
4,220
795
1,000
13
1,712
13
2,200 2
5,541

7,902
1,896
478
159 2
160 6
71 2
457
742 3
359

4,305 2
210 2
500
236
119
125

01-9

Specification dimension drawings


Weight table

Unit: kg
Machine model

D375A-6

Serial number

60001 and up

Semi-U dozer assembly (excluding oil)


q Single tilt
q Dual tilt
Reinforced type semi-U dozer assembly
q Single tilt
q Dual tilt
Reinforced type full-U dozer assembly
q Single tilt
q Dual tilt
Semi-U blade assembly
Reinforced type semi-U blade assembly
Reinforced type full-U blade assembly (with spill guard)
Straight frame
Tilt cylinder (excluding oil)
q Single tilt
q Dual tilt
Variable multi-shank ripper assembly (excluding oil)
q Shank assembly
q Ripper lift cylinder assembly
q Ripper tilt cylinder assembly
Variable giant ripper assembly (excluding oil)
q Shank assembly
q Ripper lift cylinder assembly
q Ripper tilt cylinder assembly
Radiator guard assembly (including cylinder yoke)
q Radiator guard
q Blade lift cylinder assembly
Radiator mask
Engine underguard
Power train underguard (front)
Power train underguard (rear)
Hood and side cover assembly (including air cleaner)
Fender (left)
Fender (right)
ROPS assembly
Floor frame assembly
Cab assembly
Operator seat assembly (with mechanical suspension)
Operator seat assembly (with air suspension)

01-10

10,100
10,180
10,470
18,650
11,500
11,680
6,750
7,220
8,250
1,350 2
275
270 2
6,755
470 3
270 2
240 2
6,155
650 1
270 2
240 2
2,870
1,342
290 2
140
275
220
320
337
331
372
703
591
570
64
58

D375A-6
(06)

DRAFT
Specification and technical data
Table of fuel, coolant and lubricants

Table of fuel, coolant and lubricants


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

D375A-6

01-11

DRAFT
Specification and technical data
Table of fuel, coolant and lubricants

Unit: l
D375A-6
Refilling points
Specified capacity

Refill capacity

Engine oil pan

87

86

Damper case

2.1

2.1

Power train case

275

150

Final drive case


(both sides)

61

61

Hydraulic oil system


q Single tilt, without ripper
q Single tilt with variable rippers
q Dual tilt with variable rippers

230
275
280

130

Cooling system

120

1,200

Fuel tank

01-12

D375A-6

DRAFT
D375A-6
SEN05013-00

Bulldozer
Shop Manual

D375A-6

Machine model
D375A-6

Serial number
60001 and up

10 Structure and function

D375A-6

10-1

Table of contents

Table of contents
10 Structure, function and maintenance standard
Engine and cooling system .....................................................................................................
Cooling system ....................................................................................................................
Cooling fan pump.................................................................................................................
Cooling fan motor.................................................................................................................
Power train..............................................................................................................................
Power train...........................................................................................................................
Overall drawing of power train unit ......................................................................................
Power train hydraulic equipment arrangement drawing.......................................................
Damper and universal joint ..................................................................................................
Torque converter and PTO ..................................................................................................
Torque converter control valve ............................................................................................
Main relief valve and torque converter relief valve...............................................................
Lockup clutch ECMV and stator clutch ECMV.....................................................................
Scavenging pump ................................................................................................................
Transmission control............................................................................................................
PCCS lever ..........................................................................................................................
Transmission........................................................................................................................
Transmission ECMV ............................................................................................................
Transmission lubricating oil relief valve ...............................................................................
Steering and brake control...................................................................................................
Transfer unit, bevel gear shaft and steering ........................................................................
Steering control valve ..........................................................................................................
Steering clutch ECMV and Steering brake ECMV ...............................................................
Parking brake valve .............................................................................................................
Sudden stop prevention valve..............................................................................................
Final drive ............................................................................................................................
Undercarriage and frame ........................................................................................................
Track frame..........................................................................................................................
Idler cushion.........................................................................................................................
Track roller bogie .................................................................................................................
Main frame ...........................................................................................................................
Suspension ..........................................................................................................................
Hydraulic system.....................................................................................................................
Work equipment hydraulic piping diagram...........................................................................
PPC control piping diagram .................................................................................................
Work equipment control .......................................................................................................
Hydraulic tank ......................................................................................................................
Accumulator .........................................................................................................................
PPC lock valve.....................................................................................................................
PPC valve ............................................................................................................................
Piston valve..........................................................................................................................
Quick drop valve ..................................................................................................................
Pin puller switch ...................................................................................................................
Pin puller solenoid valve ......................................................................................................
Blade control lever (only for the machine with dual tilt specification)...................................
Work equipment pump.........................................................................................................
Control valve ........................................................................................................................
Self-pressure reducing valve ...............................................................................................
Work equipment......................................................................................................................
Cylinder stay ........................................................................................................................

10-2

10-2
10- 4
10- 4
10- 6
10- 26
10- 32
10- 32
10- 34
10- 36
10- 38
10- 40
10- 46
10- 48
10- 50
10- 55
10- 56
10- 58
10- 62
10- 76
10- 81
10- 82
10- 84
10- 90
10- 92
10- 99
10- 101
10- 103
10- 108
10- 108
10- 110
10- 111
10- 112
10- 114
10- 117
10- 117
10- 121
10- 122
10- 124
10- 126
10- 127
10- 129
10- 140
10- 141
10- 142
10- 143
10- 145
10- 146
10- 158
10- 173
10- 180
10- 180

D375A-6
(04)

Table of contents

Cab .........................................................................................................................................
Cab mount ...........................................................................................................................
Cab ......................................................................................................................................
Electrical system .....................................................................................................................
Engine control......................................................................................................................
Engine control system .........................................................................................................
CRI engine control system...................................................................................................
Monitor system ....................................................................................................................
Machine monitor ..................................................................................................................
Lamp system .......................................................................................................................
Engine preheat (electrical intake air heater) control ............................................................
Palm command control system............................................................................................
Sensor .................................................................................................................................
Vehicle health monitoring system (VHMS) ..........................................................................
ORBCOMM system .............................................................................................................

D375A-6
(04)

10- 181
10- 181
10- 182
10- 184
10- 184
10- 185
10- 194
10- 196
10- 198
10- 215
10- 216
10- 217
10- 220
10- 224
10- 230

10-3

DRAFT
Engine and cooling system
Cooling system

Engine and cooling system


Cooling system

10-4

D375A-6

DRAFT
Engine and cooling system
Cooling system

A: Power train oil cooler inlet


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

Power train oil cooler

Core type

Rectangle corrugated
fin

PTO-OL

Fin pitch(mm)

8.0/2

8.0/2

8.0/2

Total heat dissipation surface(m2)

49.09 3

3.77

4.09

27.39 2

88.3 14.7
{0.9 0.15}

0 4.9
{0 0.05}

Cracking pressure of pressure valve


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

D375A-6

Hydraulic oil cooler

Aftercooler

Rectangle corrugated
Rectangle straight fin
fin

10-5

DRAFT
Engine and cooling system
Cooling fan pump

Cooling fan pump


Model : LPV90 + 30

Appearance

1. LPV90 Hydraulic pump


2. LPV30 Hydraulic pump

10-6

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

LPV90 Hydraulic pump


Appearance

D375A-6

10-7

DRAFT
Engine and cooling system
Cooling fan pump

Sectional view

IM: Control current input connector


PA: Pump discharge port
PDI: Drain port
PD2: Drain port (Plug)
PDA: Breather
PEN: Control pressure pickup port (Plug)
PEPC: EPC source pressure input port
PS: Pump suction port

10-8

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

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

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

D375A-6

q
q

The hydraulic balance is maintained properly on


this face.
The oil is sucked into and discharged from each
cylinder in cylinder block (7) through valve plate
(8).

10-9

DRAFT
Engine and cooling system
Cooling fan pump

Operation
Operation of pump
q Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane (A).
q Rocker cam (4) moves along cylindrical face (B).
As a result, angle (a) between center line (X) of
rocker cam (4) and the axis of cylinder block (7)
changes.
q Angle (a) is called the swash plate angle.

q
q

q
q

If center line (X) of rocker cam (4) matches the


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

The pump delivery is in proportion of swash plate


angle (a).

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


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

10-10

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

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

D375A-6

10-11

DRAFT
Engine and cooling system
Cooling fan pump

PC valve, EPC valve, and servo piston

IM: Control current input connector


PA: Pump discharge port
PEPC: EPC source pressure input port
Servo piston
1. Servo piston
2. Lever
3. Spring

PC valve
4. Piston
5. Seat
6. Spring
7. Spool
8. Sleeve
9. Plug
EPC valve
10. EPC valve

10-12

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

Function
q The PC valve controls the servo piston so that
the delivery (swash plate angle) is related to the
current input to the EPC valve is as shown in the
figure below.

D375A-6

10-13

DRAFT
Engine and cooling system
Cooling fan pump

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

10-14

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

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

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


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

D375A-6

10-15

DRAFT
Engine and cooling system
Cooling fan pump

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

10-16

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

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

D375A-6

10-17

DRAFT
Engine and cooling system
Cooling fan pump

LPV30 Hydraulic pump

Appearance

IM: Control electric current input connector


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

10-18

1.
2.
3.
4.

piston pump
Servo valve
Bleeder
EPC value

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

Sectional view

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

D375A-6

10-19

DRAFT
Engine and cooling system
Cooling fan pump

Function
q

The rotation and torque of the engine are transmitted to the shaft of this pump. Then, this pump
converts the rotation and torque into hydraulic
energy and discharges hydraulic oil according to
the load.
The discharge of this pump can be changed by
changing the swash plate angle in it.

The oil is sucked into and discharged from each


cylinder chamber of cylinder block (7) through
valve plate (8).

Structure
q
q
q
q
q
q
q
q
q

Cylinder block (7) is connected to shaft (1)


through splines (B).
Shaft (1) is supported by the front and rear bearings (12).
The tip of piston (6) has a spherical hollow in
which shoe (5) is being held by crimping.
Piston (6) and shoe (5) form a spherical bearing.
Shoe (5) is kept pressed against plane (A) of
rocket cam (4) and slids circularly.
Rocker cam (4) pivot on ball (11).
Piston (6) in each cylinder of cylinder block (7)
reciprocates in the axial direction.
Cylinder block (7) rotates relatively against valve
plate (8) sealing the hydraulic oil.
The hydraulic balance on the valve plate is maintained properly.

10-20

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

Operation
Operation of pump
q Cylinder block (7) rotates together with shaft (1)
and shoe (5) slides on plane (A).
q Rocker cam (4) pivots on ball (11). As a result,
angle (a) between center line (X) of rocker cam
(4) and the axis of cylinder block (7) changes.
q Angle (a) is called the swash plate angle.
q If angle (a) is made between center line (X) of
rocker cam (4) and the axis of cylinder block (7),
plane (A) works as a cam for shoe (5).
q Piston (6) reciprocates inside cylinder block (7)
and a difference is made between volumes (E)
and (F) in cylinder block (7)
q Each piston (6) sucks and discharges oil by (F) (E).
q If cylinder block (7) rotates and the volume of
chamber (E) is decreased, the oil is discharged
from chamber (E).
q The volume of chamber (F) is increased and the
oil is sucked in chamber (F).

D375A-6

If center line (X) of rocker cam (4) matches the


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

The pump delivery is in proportion to swash plate


angle (a) .

10-21

DRAFT
Engine and cooling system
Cooling fan pump

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

10-22

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

Servo valve

P: EPC valve source pressure input port


PE: Servo piston control pressure output port
PH: Pump discharge pressure input port
T: Drain port

D375A-6

1.
2.
3.
4.
5.
6.
7.

Plug
Lever
Retainer
Seat
Spool
Piston
Sleeve

10-23

DRAFT
Engine and cooling system
Cooling fan pump

A: Drain side
B: Pump discharge pressure input side
C: EPC output pressure receiving pressure

10-24

D: EPC output pressure side


P: EPC source pressure input side

D375A-6

DRAFT
Engine and cooling system
Cooling fan pump

Function
q The servo valve controls the servo piston so that
the delivery (swash plate angle) is related to the
current input to the EPC valve as shown in the
figure below.

The relationship between the EPC valve input


current (i) and EPC valve output pressure (F) is
as shown in the figure below.

D375A-6

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

10-25

Engine and cooling system


Cooling fan motor

Cooling fan motor

10-26

Type: LMF180 (150)


Appearance

P: From fan pump


T: To tank through cooler
TC: To tank

10-26

10-26

10-26
Type: LMF150
Capacity: 150 cm3/rev
Rated speed: 1,225 rpm
Rated flow: 184 l/min
Check valve cracking pressure:
68.6 kPa {0.7 kg/cm2}
Specifications

D375A-6
(04)

DRAFT
Engine and cooling system
Cooling fan motor

Sectional view

1.
2.
3.
4.
5.
6.

Output shaft
Case
Thrust plate
Shoe
Piston
Cylinder block

D375A-6

7. Valve plate
8. End cover
9. Center spring
10. Suction safety valve
11. ON/OFF pilot valve
12. Reversible valve spool
13. Speed sensor

10-27

DRAFT
Engine and cooling system
Cooling fan motor

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

10-28

D375A-6

DRAFT
Engine and cooling system
Cooling fan motor

Suction safety valve


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

When the pump is stopped


q If the engine is stopped and the shaft speed of
the fan pump lowers to 0rpm, the pressurized oil
from the pump is not supplied to port (P) any
more. As the pressurized oil is not supplied to
the (MA) side of the motor, the motor speed lowers gradually to stop.
q If the motor shaft is revolved by the force of inertia while the oil flow in the port (P) is reducing,
the oil in port (T) on the outlet side is sent by suction safety valve (1) to the (MA) side to prevent
cavitation.

Operation
When pump is started
q

If the pressurized oil from the pump is supplied


to port (P) and the pressure on (MA) side rises
and starting torque is generated in the motor, the
motor starts revolution.The pressurized oil on
the motor outlet (MB) side of the motor returns
through port (T) to the tank.

D375A-6

10-29

DRAFT
Engine and cooling system
Cooling fan motor

Function as safety valve


q The pressure in port (P) of the fan motor may
rise abnormally as in starting engine.
q Suction safety valve (1) is installed to protect the
fan system circuit in such a case.
Operation
If the pressure in port (P) rises above the cracking pressure of suction safety valve (1), valve (2)
of suction safety valve (1) opens to release the
pressurized oil into port (T).
q By this operation, generation of abnormally high
pressure in port (P) is prevented.
q

10-30

D375A-6

DRAFT
Engine and cooling system
Cooling fan motor

Operation of reversible valve


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

D375A-6

When the ON/OFF solenoid is energized


q If ON/OFF solenoid (1) is "energized", ON/OFF
selector valve (2) switches to allow the pressurized oil from the pump to flow through port (C) to
spool chamber (D).
q The pressurized oil in chamber (D) pushes valve
spool (3) to the left against spring (4) .
q Motor port (MB) connects to port (P) and pressurized oil flows in to revolve the motor in reverse (counterclockwise).

10-31

DRAFT
Power train
Power train

Power train
Power train

Outline
q The power generated by engine (1) is transmitted through universal joint (3) to torque converter
(8) while (2) reduces torsional vibration. The
torque converter (8) that uses oil as a medium
for power transmission transmits the power from
the engine to the input shaft (turbine shaft) of
transmission (9) in accordance with the change
in load.
The torque converter is equipped with a lockup
clutch, and when the speed of the output shaft of
the transmission that receives the power from
the torque converter becomes higher, the lockup
clutch is automatically engaged. When this
happens, the drive case and turbine are
combined as a unit to transmit the power from
the engine directly to the transmission input
shaft.
Transmission (9) uses a combination of planetary gear mechanisms and hydraulic clutches to
give three forward speeds and three reverse
speeds. When a gear speed is selected with the
PCCS (gearshift) lever according to the change
in load, two clutches are engaged to transmit the
power from the torque converter to transfer (15)
through its output shaft.

10-32

Transfer (15) reduces the speed of the power


transmitted, and then the combination of the
bevel pinion and bevel gear of the bevel gear
shaft unit reduces the speed further and divides
the power at right angles to the left and right to
send to the respective steering clutches (10).
Steering clutch (10) stops transmission of the
power from the bevel gear shaft unit to the final
drive to steer the machine. Moving the PCCS
(steering) lever in the direction to which the
machine turns disengages the steering clutch on
the side and the machine turns to the direction.
The turning angle is adjusted by controlling
steering brake (11) installed to the outside of the
steering clutch.
Steering brake (11) is the same disc type as that
for the steering clutch. The power output from
the steering clutch goes to final drive (12) ,
where the speed is reduced to drive sprocket
(13).
Double-reduction type final drive (12) consists of
single-reduction
spur
gear
train
and
single-reduction planetary gear train. The
sprocket drives track shoe (14) to make the
machine travel.

D375A-6

DRAFT
Power train
Power train

1. Engine (SAA6D170E-5)
2. Damper
3. Universal joint
4. Cooling fan pump (LPV90 + 30)
5. Power train pump (BAL180+112)
6. PTO
7. Work equipment pump (HPV190)
8. Torque converter
9. Transmission

D375A-6

10. Steering clutch


11. Steering brake
12. Final drive
13. Sprocket
14. Track shoe
15. Transfer
16. Scavenging pump (BAR63+277)
17. Cooling fan motor (LMF150)
18. Bevel gear and pinion gear

10-33

Power train
Overall drawing of power train unit

Overall drawing of power train unit

10-34

10-34

D375A-6
(04)

Power train
Overall drawing of power train unit

A: Torque converter inlet oil pressure pickup port


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

N: Right steering clutch pressure pickup port (RC)


P: Transmission 1st clutch pressure pickup port
(1ST)
R: Main relief pressure pickup port (TM)
1. Centralized pressure pickup port
2. Oil level gauge
3. Oil filler pipe
4. Power train and lubrication pump
5. PTO
6. Torque converter
7. Torque converter control valve
8. Transmission control valve
9. Transmission
10. Steering clutch and brake
11. Steering control valve
12. Transmission lubricating oil filter
13. Power train oil filter
14. Power train oil strainer
15. Scavenging pump
10-35

The power train unit consists of torque converter, transmission unit, and steering unit by rough
classification.
Accordingly, after removing power train unit, it
can be divided into torque converter, transmission unit, and steering unit.
The steering unit consists of transfer, bevel gear
shaft, steering clutch, and steering brake.

D375A-6
(04)

10-35

Power train
Power train hydraulic equipment arrangement drawing

Power train hydraulic equipment arrangement drawing

1. Oil cooler
2. Power train oil filter
3. Transmission lubricating oil filter
4. Centralized pressure pickup port
5. Torque converter valve
6. Transmission control valve (ECMV)
7. Steering control valve (ECMV)
8. Power train oil tank
9. Power train oil strainer
10. Power train pump (BAL180+112)
11. Scavenging pump (BAR63+277)
12. Cooling fan pump (LPV90+30)

10-36

10-36

A: Torque converter lock-up pressure pickup port


B: Torque converter stator clutch pressure pickup
port
C: Left steering clutch pressure pickup port
D: Left steering brake pressure pickup port
E: Transmission 2nd clutch pressure pickup port
F: Transmission R clutch pressure pickup port
G: Transmission 3rd clutch pressure pickup port
H: Transmission F clutch pressure pickup port
J: Right steering brake pressure pickup port
K: Right steering clutch pressure pickup port
L: Transmission 1st clutch pressure pickup port
M: Transmission 1st clutch pressure pickup port
N: Torque converter regulator pressure pickup port
P: Torque converter relief pressure pickup port
R: Main relief pressure pickup port

D375A-6
(06)

DRAFT
Power train
Power train hydraulic equipment arrangement drawing

D375A-6

10-37

DRAFT
Power train
Damper and universal joint

Damper and universal joint

10-38

D375A-6

DRAFT
Power train
Damper and universal joint

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

D375A-6

Outline
q The damper protects the power train (such as
the torque converter and transmission) by buffering torsional vibrations resulting from fluctuations in engine torque or impact torque resulting
from sudden acceleration or heavy duty operation.
The rubber couplings on the damper effciently
absorbs vibrations by rubber material's internal
damping effects and deformation as well as frictional damping effects of the rubber material.
This arrangement also helps reducing number of
components used.
Operation
q The power of engine is transmitted from flywheel
(2) through outer body (1) to rubber couplings
(7). After absorption of torsional vibrations of the
engine by the rubber coupling, power is then
transmitted to the coupling (4) via output shaft
(3). Then, power is further transmitted from the
coupling to the torque converter input shaft
through universal joint (5).

10-39

DRAFT
Power train
Torque converter and PTO

Torque converter and PTO


a PTO: Abbreviation for Power Take Off

10-40

D375A-6

DRAFT
Power train
Torque converter and PTO

D375A-6

10-41

DRAFT
Power train
Torque converter and PTO

A: To transmission control valve


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

10-42

1. Cooling fan pump mounting location


2. Torque converter outlet oil pressure sensor
mounting location
3. Work equipment pump mounting location
4.Power train and lubricating oil pump mounting
location
5.Scavenging pump mounting location
6.Torque converter control valve
7. Torque converter outlet oil temperature
sensor mounting port
8.Coupling
9. Retainer
10. Input shaft (number of teeth: 61)
11. Front housing
12. PTO idler gear (number of teeth: 77)
13.PTO idler gear shaft
14.Lockup clutch housing
15. Drive case
16.Turbine
17. Rear housing
18.Stator
19.Pump
20.Stator shaft
21. Guide
22.Retainer
23.Pump shaft
24.Transmission input shaft
25. Stator clutch hub gear
26.Stator clutch housing
27. Return spring
28. Stator clutch plate
29. Stator clutch disc
30. Stator clutch piston
31. Turbine boss
32. Lockup clutch plate
33. Lockup clutch disc
34. Lockup clutch piston
35.Scavenging pump drive gear (number of
teeth: 63)
36. Sleeve
37. Bearing race
38.Power train pump, lubricating oil pump and
cooling fan pump drive gear (number of teeth:
57)
39. Cover
40.Cover
41. Work equipment pump drive gear (number of
teeth: 57)
42.Cover
43. Strainer

D375A-6

Power train
Torque converter and PTO

10-43
The torque converter is a 3-element, 1-stage
and 1-phase type, and is integral with the transmission.The torque converter is equipped with a
wet double-disc clutch type lockup unit and a
stator clutch unit in order to reduce fuel consumption, to increase the operability, and to reduce captive consumption of the engine
horsepower.
For higher efficiency of continuous light dozing
and leveling operation, the torque converter is
locked up to transmit the engine power directly to
the transmission input shaft. Even when the
torque converter is locked up (the pump is united
with the turbine), the oil is still supplied from the
torque converter relief valve.
The oil sent from the pump to the turbine returns
to the stator. The flow of oil is obstructed by the
stator blades and becomes turbulent (it is
agitated), producing resistance against the rotation of the pump and turbine.
To reduce the resistance against the rotation of
the pump and turbine, the stator clutch is disengaged simultaneously with lockup of the torque
converter, allowing the stator to rotate freely. As
the stator turns along with the pump and turbine,
the oil returns from the turbine to the pump
smoothly with less resistance.

10-43
Pump (19) is united with coupling (8), input shaft
(10), lockup clutch housing (14), and drive case
(15), and is rotated by the engine power.
Turbine (16) is united with the turbine boss (31)
and transmission input shaft (turbine shaft) (24)
and is rotated by the oil from the pump.
Stator (18) is united with the stator shaft (20) and
stator boss (25) and is fixed to rear housing (17)
through the stator clutch unit.
The lock-up clutch unit consists of clutch plate
(28) meshed with drive case (15), clutch discs
(33) meshed with the turbine boss (31) and
clutch piston (30) that slides inside housing (14)
united with the drive case.
The stator clutch unit consists of clutch discs
(29) meshed with boss (25) splined to stator
shaft (20), clutch plate (28) supported on clutch
housing (26) and rear housing (17) with the pins,
and clutch piston (30) that slides inside the rear
housing.
The PTO unit consists of input shaft (10), idler
gear (12), scavenging pump drive gear (35),
cooling fan pump and work equipment pump
drive gear (41) and power train pump drive gear
(38).

Outline

Structure

Conditions for lockup mode and torque converter


mode
Gear speed

Forward 1st

Torque converter output shaft speed:


(rpm)
Lockup mode

Torque converter
mode

Min. 1,320
Max. 1,830

Min. 1,256
Max. 1,830

Forward 2nd

Min. 1,584

Max. 1,555

Forward 3rd

Min. 1,350

Max. 1,320

Reverse 1st
Reverse 2nd
Reverse 3rd

Min. 1,255
Min. 1,359
Min. 1,373

Max. 1,226
Max. 1,330
Max. 1,343

a While the transmission is shifting gears, the


torque converter comes into the torque converter drive mode.

D375A-6
(04)

10-43

DRAFT
Power train
Torque converter and PTO

Power transmitting route


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

When lockup clutch is "engaged" and stator


clutch is "disengaged"

As drive case (4) and turbine (6) are disconnected from


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

Drive case (4) is connected to turbine (6) and torque


converter is locked up.
Rear housing (9) and stator shaft (10) are connected to
each other to fix stator (11).

Engine power
O
Coupling (1)
O
Input shaft (2), clutch housing (3), drive case (4) and
pump (5) rotate together
O
Oil is used as medium
O
Turbine (6) and boss (7)
O
Transmission input shaft (8)

10-44

Engine power
O
Coupling (1)
O
Input shaft (2), clutch housing (3), drive case (4) and
pump (5) rotate together
O
Lockup clutch (9)
O
Turbine (6) and boss (7)
O
Transmission input shaft (8)

D375A-6

DRAFT
Power train
Torque converter and PTO

Oil flow

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

D375A-6

10-45

DRAFT
Power train
Torque converter control valve

Torque converter control valve

A: From power train pump


B: Lockup clutch oil pressure pickup port (LC)
C: Stator clutch oil pressure pickup port (SC)
1. Main relief valve and torque converter relief valve
2. Stator clutch ECMV
3. Lockup clutch ECMV
4. Torque converter inlet oil pressure sensor

10-46

D375A-6

DRAFT
Power train
Torque converter control valve

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

Identification
Pressure control
color
valve
(B)

A*******

Yellow

Without slit

E*******

Pink

With slit

Main relief valve


The main relief valve maintains each hydraulic
circuit pressure of the transmission, steering
clutch, steering brake and the lockup clutch and
stator clutch of torque converter constantly at the
set pressure.
Set pressure : 2.63 2.92 MPa {26.8
29.8 kg/cm2 } (At rated engine speed)

Fill switch
(Operation pressure:
MPa{kg/cm2})
Equipped
(0.26 {2.7})
Equipped
(0.26 {2.7})

Operated
clutches
Stator
Lockup

Lockup clutch ECMV


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

Torque converter relief valve


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

Stator clutch ECMV


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

D375A-6

10-47

DRAFT
Power train
Main relief valve and torque converter relief valve

Main relief valve and torque converter relief valve

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

10-48

D375A-6

DRAFT
Power train
Main relief valve and torque converter relief valve

Operation of main relief valve

The oil from the hydraulic pump flows through


the filter, port (A) of the torque converter valve,
and orifice (a) of torque converter relief valve (1)
to chambe (B).

Operation of torque converter relief valve

The oil from the main relief valve flows through


port (C) to the torque converter, and at the same
time, also flows through orifice (b) of torque converter relief valve (3) to chamber (D) .
When the oil pressure on the torque converter
exceeds the set pressure, the oil in chamber (D)
pushes piston (4), the reaction force of which
moves torque converter relief valve (3) to the
right to open port (C) and port (E).
Then the oil in port (C) is drained from port (E) to
the oil tank.

When the oil pressure in the circuit exceeds the


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

D375A-6

10-49

DRAFT
Power train
Lockup clutch ECMV and stator clutch ECMV

Lockup clutch ECMV and stator clutch ECMV


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

A: To clutch
P: From pump
T: Drain
DR: Drain
P1: Clutch oil pressure pickup port
P2: Pilot oil pressure pickup port
1. Fill switch connector
2. Proportional solenoid connector
3. Oil pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Oil pressure control valve
7. Nameplate

10-50

D375A-6

DRAFT
Power train
Lockup clutch ECMV and stator clutch ECMV

ECMV for lockup clutch

Operation
When traveling with torque converter working

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

At gear shift (traveling in lockup drive mode)

D375A-6

When traveling in torque converter drive mode,


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

10-51

DRAFT
Power train
Lockup clutch ECMV and stator clutch ECMV

When traveling in lockup drive mode


(Traveling in torque converter drive mode to traveling in lockup drive mode)
During filling
In pressure regulation

When traveling in lockup drive mode, current


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

10-52

If current flows in proportional solenoid (1), the


solenoid generates thrust in proportion to the
current. This thrust of the solenoid is balanced
with the sum of the thrust generated by the oil
pressure in clutch port and the reaction force of
pressure control valve spring (2), and then the
pressure is regulated.
While shifting gears, the lockup clutch oil pressure is reduced temporarily to reduce the shock
when shifting gear.
Oil pressure at this time is controlled so that the
lockup piston pushing force balances with the
inside pressure of torque converter.

D375A-6

DRAFT
Power train
Lockup clutch ECMV and stator clutch ECMV

ECMV for stator clutch

Operation
When traveling in lockup drive mode

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

D375A-6

When traveling in lockup drive mode, current


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

10-53

DRAFT
Power train
Lockup clutch ECMV and stator clutch ECMV

When traveling in torque converter drive mode


(Lockup drive mode travel o torque converter drive mode travel)
During filling
In pressure regulation

When traveling in torque converter drive mode


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

10-54

If current flows in proportional solenoid (1), the


solenoid generates thrust in proportion to the
current. This thrust of the solenoid is balanced
with the sum of the thrust generated by the oil
pressure in clutch port and the reaction force of
pressure control valve spring (2), and then the
pressure is regulated.

D375A-6

DRAFT
Power train
Scavenging pump

Scavenging pump
Type: BAR(3) 63+277

A: Discharge port
B: Small pump suction port
C: Large pump suction port
1. Small pump
2. Large pump

D375A-6

10-55

DRAFT
Power train
Transmission control

Transmission control
a Regarding the steering-related description of
the PCCS lever, refer to the "Steering and brake
control".
a PCCS: Palm Command Control System

1. Brake pedal
2. Lock lever
3. PCCS lever (Steering, forward-reverse, gearshift)
3A. Upshift switch (Gear upshifts each time this
switch is pressed)
3B. Downshift switch (Gear downshifts each
time this switch is pressed)
4. Transmission neutral switch
5. Cable
6. Transmission control valve
7. Power train controller

10-56

Lever position
[1]: Neutral
[2]: Forward
[3]: Reverse
[4]: OFF
[5]: Upshift
[6]: Downshift
[7]: Free
[8]: Lock

D375A-6

DRAFT
Power train
Transmission control

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

D375A-6

10-57

Power train
PCCS lever

PCCS lever

10-58

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

1.
2.
3.
4.

Boot
Bracket
Plate
Bolt

10-58

5. Screw
6. Lever
7. Connector

D375A-6
(04)

Power train
PCCS lever

Function
Operating effort characteristics
Operation for forward and reverse travel

The control lever is held at 3 positions: "FORWARD" , "NEUTRAL" and "REVERSE".

D375A-6
(04)

Operation for left and right steering

10-59
10-59

Free return

10-59

DRAFT
Power train
Transmission control

2. Output voltage characteristics


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

10-60

D375A-6

Power train
PCCS lever

10-61
Since gear shift during travel is possible, there is no
need to stop the machine to shift gears.
Gear shift of the machine

10-61
Gear shift operation becomes available by pushing
switch (1) or (2) when Joystick (steering, directional
and gear shift lever) is in the FORWARD or REVERSE position.
(1) The gear upshifts by one each time the "Upshift"
switch is pressed.
(2) The gear downshifts by one each time the"
Downshift" switch is pressed.
a If you carry out the gear shift, the gear speed is
indicated on the display panel.
<Ex.>
Neutral: Indicates "N".
Forward 2nd: Indicates "F2" on the display.
Reverse 3rd: Indicates "R3".
"P" is indicated when the lock lever is placed at
the "Lock" position.
Gear shift operation

D375A-6
(04)

10-61

DRAFT
Power train
Transmission

Transmission

10-62

D375A-6

DRAFT
Power train
Transmission

A:
B:
C:
D:
E:

1st clutch oil pressure pickup port


3rd clutch oil pressure pickup port
R clutch oil pressure pickup port
2nd clutch oil pressure pickup port
F clutch oil pressure pickup port

1.
2.
3.
4.

Transmission control valve


Front case
Rear case
Lubricating oil relief valve

D375A-6

10-63

DRAFT
Power train
Transmission

10-64

D375A-6

DRAFT
Power train
Transmission

5. Transmission input shaft


6. Front cover
7. Sun gear for reverse clutch (34 teeth)
8. Ring gear for reverse (hub) (91 teeth)
9. Planetary pinion for reverse clutch (25 teeth)
10. Ring gear for reverse clutch (84 teeth)
11. Sun gear for forward clutch (41 teeth)
12. Planetary pinion for forward clutch (25 teeth)
13. Ring gear for forward clutch ( 91 teeth)
14. Ring gear for 3rd clutch (91 teeth)
15. Planetary pinion for 3rd clutch (25 teeth)
16. Sun gear for 3rd clutch (41 teeth)
17. Ring gear for 2nd clutch (93 teeth)
18. Planetary pinion for 2nd clutch (23 teeth)
19. 2nd sun gear(47 teeth )
20. 1st clutch gear
21. 1st clutch piston
22. 1st clutch piston housing
23. Output shaft
24. Spacer
25. Collar
26. 1st clutch spring
27. 2nd carrier
28. Plate
29. Carrier for forward and 3rd clutches
30. Piston housing for forward and 3rd speed gear
31. Carrier for reverse clutch
32. Carrier for reverse clutch
33. Clutch piston
34. Clutch spring
35. Clutch plate
36. Clutch disc
37. Washer spring
38. Pin
39. Tie bolt

D375A-6

Outline
q The transmission is a "forward 3-speed and reverse 3-speed" transmission which consists of
the planetary gear trains and the disc clutches.
q Transmission selects and locks two clutches out
of the five sets of planetary gear trains and disc
clutches hydraulically by using the control valve
to select one travel direction and one gear
speed.
q The transmission transfers the power received
by the transmission input shaft to the output
shaft by changing the gear speed (forward
1st-3rd or reverse 1st-3rd) with any combination
of the forword or reverse clutch, and one of three
speed clutches.
No. of plates and discs used
Clutch No.
R clutch
F clutch
3rd clutch
2nd clutch
1st clutch

Number of plates Number of discs


6
6
5
6
4
4
3
3
5
6

Combinations of clutches at respective gear speeds


and reduction ratio
Gear speed
Forward 1st
Forward 2nd
Forward 3rd
Neutral
Reverse 1st
Reverse 2nd
Reverse 3rd

Clutches
engaged
F 1st
F 2nd
F 3rd
(*1)
R 1st
R 2nd
R 3rd

Reduction ratio
3.220
1.745
1.000
2.471
1.339
0.769

*1: The 1st or 2nd clutch is filled with low-pressure


oil.

10-65

DRAFT
Power train
Transmission

Disc clutch
Structure

q
q

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


discs (4), pin (5), return spring (6), and washer
spring (7) to fix ring gear (1).
Inside teeth of disc (4) are engaged with outside
teeth of ring gear (1).
Plate (3) and clutch housing (8) are assembled
with pin (5).

Operation
When clutch is "engaged" (locked)

The oil from ECMV is routed to the back of piston


(2) through oil passage of clutch housing (8) and
pushes piston (2) leftward.
q Piston (2) presses plate (3) closely against disc
(4) to stop rotation of disc (4) by using friction
force generated between them.
q Since inside teeth of disc (4) are engaged with
outside teeth of ring gear (1), the ring gear (1) is
locked.
When clutch is "disengaged" (released)
q

q
q

10-66

When the supply of oil from ECMV is shut off,


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

D375A-6

DRAFT
Power train
Transmission

Oil passage in speed clutch

q
q

When the PCCS lever is in the "Neutral" position


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

D375A-6

10-67

DRAFT
Power train
Transmission

Operation of transmission
Forward 1st

10-68

D375A-6

DRAFT
Power train
Transmission

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

D375A-6

10-69

DRAFT
Power train
Transmission

Forward 2nd

10-70

D375A-6

DRAFT
Power train
Transmission

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

D375A-6

10-71

DRAFT
Power train
Transmission

Forward 3rd

10-72

D375A-6

DRAFT
Power train
Transmission

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

D375A-6

10-73

DRAFT
Power train
Transmission

Reverse 1st

10-74

D375A-6

DRAFT
Power train
Transmission

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

D375A-6

10-75

DRAFT
Power train
Transmission ECMV

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

10-76

D375A-6

DRAFT
Power train
Transmission ECMV

A: 1st clutch oil pressure pickup port


B: 3rd clutch oil pressure pickup port
C: R clutch oil pressure pickup port
D: 2nd clutch oil pressure pickup port
E: F clutch oil pressure pickup port
F: To clutch
P: From pump
T: Drain
1. 3rd clutch proportional solenoid
2. 1st clutch proportional solenoid
3. R clutch proportional solenoid
4. 2nd clutch proportional solenoid
5. F clutch proportional solenoid
6. 3rd clutch fill switch
7. 2nd clutch fill switch
8. 1st clutch fill switch
9. R clutch fill switch
10. F clutch fill switch
11. Connector for 1st clutch proportional solenoid
12. Connector for 3rd clutch proportional solenoid
13. Connector for R clutch proportional solenoid
14. Connector for 2nd clutch proportional solenoid
15. Connector for F clutch proportional solenoid
16. Connector for 3rd clutch fill switch
17. Connector for 2nd clutch fill switch
18. Connector for 1st clutch fill switch
19. Connector for R clutch fill switch
20. Connector for F clutch fill switch
21. Block
22. Pressure control valve
23. Oil pressure detection valve
24. Spring for pressure control valve

D375A-6

10-77

DRAFT
Power train
Transmission ECMV

Outline of ECMV
q The ECMV consists of a pressure control valve
and a fill switch.
q Pressure control valve
A proportional solenoid in this valve receives the
current sent from the controller and this valve
converts it to oil pressure.
q Fill switch
This switch detects that the clutch is filled with oil
and has the following functions.
1. Outputs a signal (a fill signal) to the controller to
notify that filling is completed when the clutch is
filled with oil.
2. Keeps outputting signals (fill signals) to the
controller while oil pressure is applied to the
clutch to notify whether oil pressure is applied or
not .

ECMV and proportional solenoid


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

Thrust - Oil pressure characteristics of proportional solenoid

Phase A: Before shifting gear (oil is drained)


Phase B: Filling phase
Phase C: Pressure build-up phase
Phase D: Filling phase (during triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller does not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (phase
D).

10-78

ECMV and fill switch


For each ECMV, a fill switch is installed.
When the clutch is filled with oil, the fill switch is
turned "ON" by the pressure of the clutch. The oil
pressure starts to build up according to this
signal.

D375A-6

DRAFT
Power train
Transmission ECMV

Operation of ECMV
q ECMV is controlled with the command current
sent from the controller to the proportional solenoid and the fill switch output signal.
The proportional solenoid command current of
ECMV, clutch input pressure, and fill switch
output signal change with time shown below.

Before shifting gear (oil is drained) (Phase A in


chart)

Phase A: Before shifting gear (oil is drained)


Phase B: Filling phase
Phase C: Pressure build-up phase
Phase D: Filling phase (during triggering)
Point E: Start of filling
Point F: Finish of filling
a The logic is so made that the controller does not
recognize completion of filling even if the fill
switch is turned "ON" during triggering (phase
D).
q When gear is shifted with gear shift switch, the
clutch discs and plates are pressed by piston. If
high pressure is suddenly applied, the piston
suddenly engages the clutch, causing sudden
start of the machine and excessive shock.
ECMV reduces a shock at the start of the
machine by increasing the oil pressure applied
to the piston gradually to set pressure, and
allows the clutch to be smoothly "engaged". It
aims to increase durability of the components on
the power transmitting route and enhances an
operator comfort.

D375A-6

Under the condition where any current is not


sent to the proportional solenoid (1), pressure
control valve (3) drains the oil from clutch port
(A) through drain port (T).
Also at this time, fill switch (5) is turned "off"
because oil pressure is not applied to pressure
detection valve (4).

10-79

DRAFT
Power train
Transmission ECMV

Filling phase (Phase B in chart)

When current is supplied to proportional solenoid (1) with no oil in the clutch, the force exerted
by the oil pressure, that is equal to the thrust of
the solenoid, develops in chamber (B) and pushes pressure control valve (3) to the right. As a result, pump port (P) and clutch port (A) are
opened and oil starts filling the clutch. When the
clutch is filled with oil, pressure detection value
(4) actuates to turn "ON" fill switch (5).

10-80

Pressure adjustment (Range C in chart)

When current flows through proportional solenoid (1), the solenoid generates thrust in proportion to the current. The clutch circuit pressure
builds up until the thrust of the solenoid is balanced with the sum of the force exerted by the oil
pressure in clutch port and the force of pressure
control valve spring (2), and then the pressure is
settled.

D375A-6

DRAFT
Power train
Transmission lubricating oil relief valve

Transmission lubricating oil relief valve

1. Lubricating oil pressure measurement plug


2. Lubricating oil relief value spool
3. Valve body

Outline
q The lubricating oil relief valve is installed to the
right side face of the transmission, and acts to
prevent any abnormal pressure in the transmission lubricating oil.
Cracking pressure: 0.26 MPa {2.7 kg/cm2}

D375A-6

10-81

DRAFT
Power train
Steering and brake control

Steering and brake control


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

10-82

D375A-6

DRAFT
Power train
Steering and brake control

1. Brake pedal
2. Lock lever
3. PCCS lever(steering, forward-reverse, gear shift)
4. Power train controller
5. Limit switch
6. Steering ECMV
7. Brake valve
8. Parking brake lever (from lock lever)
9. Cable
10. Rod (from brake pedal)
11. Potentiometer

Outline
q PCCS lever (3) sends electric signals to power
train controller (4). After receiving the signals,
power train controller (4) sends a proportional
current to the steering ECMV (6) to operate the
steering clutch and brake.
q Brake pedal (1) sends electric signals to power
train controller (4) through the potentiometer
(11). Upon receiving those signals, power train
controller (4) sends a proportional current to
steering ECMV (6) to operate the brake. In this
case, the right and left brakes operate at the
same time to activate braking. Rod (10), as an
emergency brake operating device, operates the
brake through brake valve (7). (only when the
brake pedal is depressed fully)
q If you completely tilt PCCS lever (3) If you slightly tilt PCCS lever (3) leftward, the left steering
clutch is partially disengaged, causing the machine to make a gradual left turn.

D375A-6

Positions of levers and pedals


[1]: Neutral
[2]: Forward straight-travel
[3]: Reverse straight-travel
[4]: Left clutch OFF
[5]: Left clutch OFF, Left brake ON
[6]: Right clutch OFF
[7]: Right clutch OFF, Right brake ON
[8]: Brake "released"
[9]: Brake ON
[10]: Free
[11]: Lock

If you completely tilt PCCS lever (3) leftward, the


left steering clutch is "disengaged" completely
and the left steering brake is "applied" , causing
the machine to make a sharp left turn.
The lock lever (2) is connected to parking brake
lever (8) and serves as a parking brake lever.

10-83

DRAFT
Power train
Transfer unit, bevel gear shaft and steering

Transfer unit, bevel gear shaft and steering


Machines without VHMS controller

1. Transmission
2. Input shaft
3. Steering unit
4. Breather
5. Parking brake valve
6. L.H. steering brake ECMV
7. R.H. steering brake ECMV
8. Transmission output shaft speed sensor
9. Filter

10-84

10. L.H. steering clutch ECMV


11. R.H. steering clutch ECMV
12. Sudden stop prevention valve

D375A-6

DRAFT
Power train
Transfer unit, bevel gear shaft and steering

Machines equipped with VHMS controller

1. Transmission
2. Input shaft
3. Steering unit
4. Breather
5. Parking brake valve
6. L.H. steering brake ECMV
7. R.H. steering brake ECMV
8. Transmission output shaft speed sensor
9. Filter

D375A-6

10. L.H. steering clutch ECMV


11. R.H. steering clutch ECMV
12. Sudden stop prevention valve

10-85

DRAFT
Power train
Transfer unit, bevel gear shaft and steering

Transfer unit and bevel pinion


Machines without VHMS controller

1. Input shaft
2. Drive gear (35 teeth)
3. Transmission output shaft speed sensor
4. Rear cover
5. Bearing cage
6. Driven gear (33 teeth)
7. Bevel pinion (23 teeth)
8. Bevel gear (40 teeth)

10-86

Outline
q The transfer unit and bevel pinion are installed at
the rear part inside the steering case, and input
shaft (1) receives the power from the transmission output shaft.
q The transfer unit consists of drive gear (2) and
driven gear (6) to reduce the power speed from
input shaft (1), transferring it to bevel pinion (7).
q It is equipped with transmission output shaft
speed sensor (3) to send the electric signals of
speed of drive gear (2) to the power train controller.

D375A-6

DRAFT
Power train
Transfer unit, bevel gear shaft and steering

Machines equipped with VHMS controller

1. Input shaft
2. Drive gear (35 teeth)
3. Transmission output shaft speed sensor
4. Rear cover
5. Torque converter output speed sensor
6. Bearing cage
7. Driven gear (33 teeth)
8. Bevel pinion (23 teeth)
9. Bevel gear (40 teeth)

D375A-6

Outline
q The transfer unit and bevel pinion are installed at
the rear part inside the steering case, and input
shaft (1) receives the power from the transmission output shaft.
q The transfer unit consists of drive gear (2) and
the driven gear (7) to reduce the power speed
from the input shaft (1), transferring it to bevel
pinion (8).
q It is equipped with transmission output shaft
speed sensor (3) to send the electric signals of
speed of drive gear (2) to the power train controller.

10-87

DRAFT
Power train
Transfer unit, bevel gear shaft and steering

Bevel gear shaft, steering clutch and brake

10-88

D375A-6

DRAFT
Power train
Transfer unit, bevel gear shaft and steering

1. Output shaf
2. Sleeve
3. Brake cage
4. Brake spring
5. Brake case
6. Brake piston
7. Torque pin
8. Blake plate (each side: 9 plates)
9. Spacer
10. Brake disc (each side: 9 discs)
11. Brake hub
12. Brake stopper
13. Pipe
14. Bearing cage
15. Bevel gear shaft
16. Bevel gear shaft
17. Bevel gear (40 teeth)
18. Bearing cage
19. Clutch hub
20. Clutch stopper
21. Spacer
22. Clutch plate (each side: 9 plates)
23. Clutch disc (each side: 9 discs)
24. Torque pin
25. Clutch piston
26. Clutch spring
27. Clutch housing
28. Clutch cage

D375A-6

Outline
q The steering clutch is wet-type, multiple-disc,
spring-applied type. If you operate the PCCS lever, the controller outputs a proportional solenoid current to hydraulically operate the steering
clutch ECMV. The steering clutch works in conjunction with the steering brake.
q The steering brake is wet type multiple-disc,
spring-applied type. If you operate the brake
pedal and PCCS lever, the controller outputs a
proportional solenoid current to hydraulically operate the steering brake ECMV. The steering
brake works in conjunction with the steering
clutch.
q When the engine is stopped, the steering brake
is "applied" since the pressure acting on the
back of the brake piston lowers, even if you do
not depress the brake pedal. Since the brake is
released as the oil pressure in the circuit goes up
when the engine restarts, the parking brake lever must be set to "LOCK" position.
q The lubrication method is forced lubrication type,
which makes oil from the power train oil cooler
flow through the passage in the steering case to
the housing and cage, and up to the discs and
plates.

10-89

DRAFT
Power train
Steering control valve

Steering control valve

10-90

D375A-6

DRAFT
Power train
Steering control valve

A: Left clutch pressure pickup port


B: Right clutch pressure pickup port
C: Left brake pressure pickup port
D: Right brake pressure pickup port
E: To left clutch
F: To left lubrication circuit
G: To left brake
H: To right clutch
J: To right lubrication circuit
K: To right brake
L: Bevel gear shaft lubricating oil inlet port
M: To pin puller solenoid valve
N: From pin puller solenoid valve
P: From pump
1. Left steering clutch ECMV
2. Right steering clutch ECMV
3. Sudden stop prevention valve
4. Parking brake valve
5. Left steering brake ECMV
6. Right steering brake ECMV
7. Filter
8. Valve seat

D375A-6

Outline
q
Four ECMV's are installed on the valve seat of
the steering control valve to control the steering
clutch and steering brake.
q The steering control valve is located in the circuit
between the power train pump and the pistons of
the steering clutch and steering brake. It consists of two sets of the steering clutch ECMV
(L.H. and R.H.) and two sets of the steering
brake ECMV (L.H. and R.H.).
q The steering control valve sends the oil from the
power train pump to the both left and right sides
of steering clutches and steering brakes to control respective disc clutches and disc brakes.
q When the PCCS lever is leaned to the right or
left, the steering clutch is disengaged. The steering brake will operate by leaning further the
PCCS lever.
q The controller sends signals to each ECMV according to the right or left travel of the PCCS lever and controls the clutch and brake for the
gradual or sharp turns.
q When the brake pedal is depressed, the controller sends the command current to the steering
brake ECMV according to the pedal travel to apply the L.H. and R.H. brakes to stop the machine.
q The controller that is connected electrically to
the PCCS lever and brake pedal operates the
steering clutch and steering brake by controlling
each ECMV.
q The sudden stop prevention valve is installed to
prevent the machine from stopping suddenly
when a failure occurs in the electrical system.
q When the parking brake lever is set in the "lock"
position, the parking brake valve port is switched
to drain the oil between the L.H. and R.H. steering brake ECMV and the brake piston to apply
the brake. The parking brake valve is connected
to the brake pedal by the linkage.

10-91

DRAFT
Power train
Steering clutch ECMV and Steering brake ECMV

Steering clutch ECMV and Steering brake ECMV


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

A: To clutch or brake
P: From pump
T: Drain
Dr: Drain
P1: Clutch or brake oil pressure pickup port

*1:

1. Fill switch connector


2. Proportional solenoid connector
3. Pressure detection valve
4. Fill switch
5. Proportional solenoid
6. Pressure control valve
7. Nameplate (*1)

Outline
q Each ECMV keeps the steering clutch pressure
and steering brake pressure to the set pressure
and switches the circuit to the piston chamber of
the steering clutch and steering brake.

10-92

Clutch to use ECMV

Stamp of the name


plate

Steering clutch, Steering


brake

R*******

D375A-6

DRAFT
Power train
Steering clutch ECMV and Steering brake ECMV

Outline of ECMV
q The ECMV consists of a pressure control valve
and a fill switch.
q Pressure control valve
A proportional solenoid in this valve receives a
current sent from the steering controller and this
valve converts it to an oil pressure.
q Fill switch
This is a switch to detect that a clutch or brake is
filled with oil and has the following functions.
1. At the moment when the clutch or brake is filled
with oil, the fill switch outputs the signal (fill
signal) to the controller to notify the finishing of
filling.
2. While the oil pressure is applied to the clutch or
brake, the fill switch outputs the signal (fill signal)
to the controller to notify the presence of the oil
pressure.
ECMV and proportional solenoid
Each ECMV is equipped with a proportional solenoid.
The solenoid generates thrust according to the
command current from the controller. The thrust
generated by the proportional solenoid acts on
the spool of the pressure control valve and the
valve generates the oil pressure. Accordingly,
controlling the command current that changes
the thrust to operate the pressure control valve
allows for controlling the oil flow and oil pressure.

ECMV and fill switch


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

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

D375A-6

10-93

DRAFT
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in
"free" position: Straight travel
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "released", and parking brake is "released".)

q
q

When the PCCS lever is in "neutral" position and


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

10-94

The oil in port (Pb) of the brake ECMV flows in


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

D375A-6

DRAFT
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is "operated to the left halfway", brake pedal is "released", and parking brake lever
is in "free" position: Gradual left turn
(L.H. clutch is "disengaged", L.H. brake is "semi-released", R.H. clutch is "engaged", R.H. brake is "released",
and parking brake is "released".)

When the PCCS lever is "operated halfway to


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

D375A-6

The oil in port (Pb) of the brake ECMV flows in


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

10-95

DRAFT
Power train
Steering clutch ECMV and Steering brake ECMV

When the parking brake lever is in "free" position, as the parking brake valve is closed, the oil
in the brake circuit is not drained.

10-96

D375A-6

DRAFT
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is "operated fully to the left", brake pedal is "released", and parking brake lever is
in "free" position: Sharp left turn
(L.H. clutch is "disengaged", L.H. brake is "applied", R.H. clutch is "engaged", R.H. brake is "released", and
parking brake is "released".)

When the PCCS lever is moved from "halfway to


left" to "fully to left" position, proportional solenoid (5) of the L.H. brake ECMV is de-energized
and the sealing part by ball (6) is fully opened.
Since the oil in port (E) is drained through the
sealing part, valve (7) is moved to the right by the
force of spring (8) to disconnect port (Pb) from
(B) and connect port (B) to port (Dr). At this time,
the oil from the port behind the brake piston is
drained through port (B) and the brake is "applied" by the force of the brake spring.
The oil from the power train pump flows through
port (Pb) of the brake ECMV and orifice (b), then
it is drained through sealing part by ball (6).

D375A-6

q
q

The oil pressure in the clutch circuit, etc. is maintained by orifice (b).
When the parking brake lever is in "free" position, as the parking brake valve is closed, the oil
in the brake circuit is not drained.

10-97

DRAFT
Power train
Steering clutch ECMV and Steering brake ECMV

When PCCS lever is in "neutral", brake pedal is "depressed", and parking brake lever is in "free" position: Stop
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "released".)

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

10-98

D375A-6

DRAFT
Power train
Parking brake valve

Parking brake valve

1. Spool
2. Valve body

D375A-6

Outline
q The parking brake valve is installed to the steering control valve, and spool (1) operates with the
parking brake lever.
q When the parking brake lever is in lock" position, the brake is applied by draining the pressurized oil for the L.H. and R.H. steering brakes.

10-99

DRAFT
Power train
Parking brake valve

When PCCS lever is in "neutral" position, brake pedal is "released", and parking brake lever is in
"lock" position : Parking
(L.H. and R.H. clutches are "engaged", L.H. and R.H. brakes are "applied", and parking brake is "applied".)

q
q

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


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

10-100

D375A-6

DRAFT
Power train
Sudden stop prevention valve

Sudden stop prevention valve

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

D375A-6

10-101

DRAFT
Power train
Sudden stop prevention valve

10-102

D375A-6

DRAFT
Power train
Final drive

Final drive

Outline
q The final drive consists of a single-reduction
spur gear set and a singal-reduction planetary
gear train. The lubrication is of splash type using
the rotation of the gears.
The final drive can be removed and installed as
a single unit.
q Floating seal (1) is installed to the rotating portion of the sprocket to prevent the entry of dirt or
sand and to prevent leakage of lubricating oil.

D375A-6

10-103

DRAFT
Power train
Final drive

10-104

D375A-6

DRAFT
Power train
Final drive

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

D375A-6

10-105

DRAFT
Power train
Final drive

Path of power transmission

10-106

D375A-6

DRAFT
Power train
Final drive

The power from the bevel gear shaft and steering clutch is transmitted to No. 1 pinion (15). It
then passes through No. 1 gear (13), which is
meshed with the No. 1 pinion, and is transmitted
to sun gear (2) to rotate it.
The rotation of sun gear (2) is transmitted to
planetary pinions (10), but ring gear (11), which
is meshed with the planetary pinions, is fixed to
cover (9), so the planetary pinions rotate along
the ring gear while moving around the sun gear.
Then, the rotating force of sun gear (2) functions
as the rotating force of carrier (3) , which
supports the planetary pinions, and is transmitted to sprocket hub (4).
The rotating direction of carrier (3) is the same
as that of sun gear (2).
The rotating force transmitted to sprocket hub
(4) is transmitted to sprocket teeth (7).

D375A-6

10-107

DRAFT
Undercarriage and frame
Track frame

Undercarriage and frame


Track frame

1. Idler
2. Recoil spring assembly
3. Idler cushion
4. Track frame
5. Sprocket
6. Sprocket cover
7. Track roller bogie
8. Track roller
9. Cap
10. Idler yoke
11. Cylinder
12. Guide

Outline
q The track rollers are mounted on the K-shaped
bogies, thereby increasing the actual contact
area between ground and the track even on an
uneven ground to increase drawbar pull.
q Because a rubber pad is mounted on a
K-shaped bogie, the shock from a road surface
is absorbed.
Track roller arrangement
Track roller flange type
1st

2nd

3rd

4th

5th

6th

7th

8th

S: Single flange type


D: Double flange type

10-108

D375A-6

DRAFT
Undercarriage and frame
Track frame

D375A-6

10-109

Undercarriage and frame


Idler cushion

Idler cushion

1. Yoke
2. Nut
3. Retainer
4. Recoil spring
5. Rod
6. Spring cylinder
7. Retainer
8. Holder
9. Piston
10. Lubricator (for pumping in and discharging
grease)
11. Grease chamber cylinder

10-110

10-1 0

10-1 0
Outline
Pumping in or discharging grease from lubricator
(10) moves rod (5) forward or backward to adjust
track tension. The recoil spring (4) acts to dampen
any sudden shock brought to bear on the idler.

D375A-6
(04)

Undercarriage and frame


Track roller bogie

Track roller bogie

1. Guide
2. Cap
3. Track roller assembly (double flange type)
4. Major bogie
5. Rubber mount
6. Miner bogie
7. Track roller assembly
8. Cover

D375A-6
(04)

10-1 1

10-1 1
Outline
q The track roller is mounted on the miner bogie
(6) so that the track roller and track shoe can be
touched constantly.
q The vibration from a road surface is absorbed by
the rubber mount (5).

10-111

DRAFT
Undercarriage and frame
Main frame

Main frame

10-112

D375A-6

DRAFT
Undercarriage and frame
Main frame

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

D375A-6

10-113

DRAFT
Undercarriage and frame
Suspension

Suspension

10-114

D375A-6

DRAFT
Undercarriage and frame
Suspension

1. Equalizer bar
2. Pivot shaft assembly
3. Cover
4. Thrust plate
5. Thrust plate
6. Pivot shaft
7. Seal cage cover
8. Cover
9. Seal
10. Bushing

D375A-6

11. Side pin


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

10-115

DRAFT
Undercarriage and frame
Suspension

*1
*2

. Indicates the left suspension of single tilt specification machines.


. Indicates the right suspension of single tilt specification machines.
Indicates the left and right suspension of dual tilt specification machines.

10-116

D375A-6

Hydraulic system
Work equipment hydraulic piping diagram

Hydraulic system

10-1 7

Work equipment hydraulic piping diagram

10-1 7

Blade system

10-1 7

Semi-U dozer + Single tilt

1. Blade tilt cylinder


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

D375A-6
(04)

10-117

DRAFT
Hydraulic system
Work equipment hydraulic piping diagram

Full U - Dozer with dual tilt function

1. Blade tilt cylinder


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

10-118

D375A-6

Hydraulic system
Work equipment hydraulic piping diagram

Ripper system

10-1 9

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

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

D375A-6
(04)

10-119

Hydraulic system
Work equipment hydraulic piping diagram

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

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

10-120

D375A-6
(04)

Hydraulic system
PPC control piping diagram

PPC control piping diagram

10-121

Blade and ripper control


(Figure shows a dual tilt specification machine)

10-121

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

D375A-6
(04)

10-121

DRAFT
Hydraulic system
Work equipment control

Work equipment control


q

The drawing shows a dual tilt dozer and pin puller installed machine.

10-122

D375A-6

DRAFT
Hydraulic system
Work equipment control

1. Work equipment lock lever


2. Blade control lever
3. Tilt/pitch selector switch (only for dual tilt dozer specification)
4. Ripper control lever (only for ripper installed machine)
5. Pin puller swith (only for giant ripper installed machine)
6. PPC lock valve
7. Work equipment lock switch
Lever positions
[1] : Blade "HOLD"
[2] : Blade "LOWER"
[3] : Blade "FLOAT"
[4] : Blade "RAISE"
[5] : Blade "LEFT TILT/*PITCH BACK"
[6] : Blade "RIGHT TILT/*PITCH DUMP"
* Activated when the pitch selector switch is turned
"ON" (dual tilt specification only)
[7] : Ripper "HOLD"
[8] : Ripper "RAISE"
[9] : Ripper "LOWER"
[10] : Ripper "TILT IN"
[11] : Ripper "TILT BACK"
[12] : FREE
[13] : LOCK
[14] : Dual tilt selector switch "OFF"
[15] : Dual tilt selector switch "ON"
[16] : Pitch selector switch "OFF" auto return
[17] : Pitch selector switch "ON"
[18] : Pin puller switch "PUSH OUT"
[19] : Pin puller switch "PUSH IN"
Outline
q The work equipment control employs a PPC system which uses PPC valves to move respective
spools of the control valve.
q Work equipment lock lever (1) is interconnected
with PPC lock valve (6), and when it is set to the
"LOCK" position, the flow of oil in the PPC circuit
is stopped.
q Work equipment lock lever (1) is also interlocked
with work equipment lock switch (7). When work
equipment lock lever (1) is set to "LOCK" position, work equipment lock switch (7) is turned
"OFF" and engine is ready to start.
When work equipment lock lever (1) is set to
"FREE" position, work equipment lock switch (7)
is turned "ON" and engine is not ready to start in
this circuit.

D375A-6

10-123

DRAFT
Hydraulic system
Hydraulic tank

Hydraulic tank

10-124

D375A-6

DRAFT
Hydraulic system
Hydraulic tank

1. Oil filler port cap


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

Specified value
Tank capacity (l)
Hydraulic tank Level inside
tank

210

Hi (l)

144

Center (l)

130

Low (l)

112

Cracking pressure of pressure valve


(kPa {kg/cm2})
Breather
Operating pressure of vacuum valve
(kPa {kg/cm2})

17 2.5
{0.17 0.025}
2 0.3
{0.02 0.003}
Specified value

Cracking pressure
(kPa{kg/cm2})

150 30
{1.5 0.3}

Mesh size (mm)

30/8

Filtering area (cm2)

17600

Filtering oil flow (l/min)

720

Strainer
(over flow)

Mesh size (mm)

40

Strainer
(suction)

Mesh size
(mm)
Filtration area
(cm2)

Hydraulic
oil filter

D375A-6

105
3,600

10-125

DRAFT
Hydraulic system
Accumulator

Accumulator
For ppc valve

1. Gas plug
2. Shell
3. Poppet
4. Holder
5. Bladder
6. Oil port
Specifications
Type of gas: Nitrogen gas
Gas volume: 300 cc
Max. working pressure: 3.1 MPa {32 kg/cm2}
Min. working pressure: 1.2 MPa {12 kg/cm2}

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

10-126

D375A-6

DRAFT
Hydraulic system
PPC lock valve

PPC lock valve


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

Outline
q The PPC lock valve is installed in the PPC circuit
between the PPC charge valve and PPC valve.
If the work equipment lock lever is placed at the
LOCK position, the PPC lock valve interlocked
with the work equipment lock lever is actuated to
stop the oil in the PPC circuit, preventing the
work equipment from moving.

D375A-6

10-127

DRAFT
Hydraulic system
PPC lock valve

10-128

D375A-6

DRAFT
Hydraulic system
PPC valve

PPC valve
Blade PPC valve
General view

P: From self-pressure reducing valve


P1: To blade lift valve(LOWER) PPC port
P2: To blade lift valve(RAISE) PPC port
P3: To blade tilt valve(LEFT TILT) PPC port
P4: To blade tilt valve(RIGHT TILT) PPC port
T: To hydraulic tank

D375A-6

10-129

DRAFT
Hydraulic system
PPC valve

Sectional view

1. Spool
2. Metering spring
3. Centering spring
4. Piston
5. Disc
6. Nut (for lever connection)
7. Joint

10-130

8. Plate
9. Retainer
10. Valve body
11. Filter

D375A-6

DRAFT
Hydraulic system
PPC valve

Operation
When in Neutral
Blade lift valve
q Ports (A) and (B) of the blade lift valve of the control valve and ports (P1) and (P2) of the PPC
valve are connected through fine control hole (f)
of spool (1) to drain chamber (D).

D375A-6

Blade tilt valve


q Ports (C) and (D) of the blade tilt valve of the
control valve and ports (P3) and (P4) of the PPC
valve are connected through fine control hole (f)
of spool (1) to drain chamber (D).

10-131

DRAFT
Hydraulic system
PPC valve

When blade control lever is in fine control range


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

10-132

D375A-6

DRAFT
Hydraulic system
PPC valve

When blade control lever is in fine control range


(When blade control lever is returned)
q When disc (5) begins to return, spool (1) is
pushed up by the force of centering spring (3)
and the force exerted by the pressure at port
(P1) .
q Because of this, fine control hole (f) is connected
to drain chamber (D), and the pressurized oil at
port (P1) is released.
q When the pressure in port (P1) lowers too much,
spool (1) is pushed down by metering spring (2)
and fine control hole (f) is disconnected from
drain chamber (D) and connected to pump pressure chamber (PP) almost simultaneously.
Then, the oil at the pump pressure is supplied
until the pressure in port (P1) is restored to the
level corresponding to the position of the lever.
q When the control valve spool returns, the oil in
drain chamber (D) flows in through fine control
hole (f') of the valve which is not operated and
then flows through port (P2) into port (A) to supply oil.

D375A-6

When blade control lever is operated to stroke


end
q When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control
hole (f) is disconnected from drain chamber (D)
and connected to pump pressure chamber (PP).
q Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (B) and pushes
the control valve spool.
q The oil returning from port (A) flows through port
(P2) and fine control (f') into drain chamber (D).

10-133

DRAFT
Hydraulic system
PPC valve

When blade control lever is operated to "Float"


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

10-134

D375A-6

DRAFT
Hydraulic system
PPC valve

Ripper PPC valve


General view

P: From self-pressure reducing valve


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

D375A-6

10-135

DRAFT
Hydraulic system
PPC valve

Sectional view

10-136

D375A-6

DRAFT
Hydraulic system
PPC valve

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

D375A-6

10-137

Hydraulic system
PPC valve

10-138
Operation
When ripper control lever is in Neutral
10-138
Ports (A) and (B) of the control valve and ports (P1)
and (P2) of the PPC valve are connected to drain
chamber (D) through fine control hole (f) of spool (1)
.

As a result, spool (1) moves up and down so that


the force of metering spring (2) is balanced with
the force exerted by pressure in port (P1).The
positional relationship between spool (1) and
valve body (10) [where fine control hole (f) is between drain chamber (D) and pump pressure
chamber (PP)] does not change until retainer (9)
comes in contact with spool (1).
Since metering spring (2) is compressed in proportion to the travel of the control lever, the pressure in port (P1) rises in proportion to the travel
of the control lever.
The control valve spool moves to a position
where the pressure of port (A) (same as pressure at port (P1)] and the force of the return
spring of the control lever.

When ripper control lever is in fine control range10-138


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

10-138

D375A-6
(06)

DRAFT
Hydraulic system
PPC valve

When ripper control lever is in fine control range


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

D375A-6

When ripper control lever is operated to stroke


end
q When disc (5) pushes down piston (4) and retainer (9) pushes down spool (1), fine control
hole (f) is disconnected from drain chamber (D)
and connected to pump pressure chamber (PP).
q Accordingly, the pilot oil flows through fine control hole (f) and port (P1) into port (A) and pushes
the control valve spool.
q The oil returning from port (B) flows through port
(P2) and fine control hole (f') into drain chamber
(D).

10-139

DRAFT
Hydraulic system
Piston valve

Piston valve
For blade lift cylinder
Outline
q The piston valve is installed on the piston in the
blade lift cylinder. When the piston reaches its
stroke end, the valve releases the oil from the
work equipment pump to reduce the oil pressure
being exerted on the piston.
In addition the piston valve relieves the shock
which occurs when the piston comes into
contact with the cylinder head or the bottom and
serves to reduce the subsequent surge pressure
in the cylinder by letting the oil escape from the
cylinder before the piston reaches its stroke end.

2. Piston valve OPEN


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

Operation
1. Piston valve CLOSED
Pressurized oil from the work equipment pump acts
on piston (2) and piston valve (3).
Then, piston valve (3) is pushed to the right and contacts the tapered part of piston valve seat (4) to seal
in the oil. As a result, the pressure in the cylinder rises to move piston (2) to the right.

10-140

D375A-6

DRAFT
Hydraulic system
Quick drop valve

Quick drop valve


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

2. While lowering
Pressurized oil from the cylinder head end flows into
port (C) through port (B).
At this time, the oil flow is restricted by orifice (A)
provided along the way, causing a differential pressure accross the orifice. When the pressure of port
(B) becomes greater than the force of spring (4), it
compresses the spring and moves spool (2) and
check valve (3) to the right.
When the spool and the check valve have moved,
the circuit connecting parts (B) and (A) is made, part
of the oil flowing from the cylinder head end to port
(C) enters the passage that connects part (A) to the
cylinder bottom end, and merged with the oil from
the control valve, and flows to the cylinder bottom
end.
Thus, the blade lowering speed increases in accordance with the amount of oil that flows to the bottom
of the cylinder and reduces the formation of vacuum
at the bottom end of the cylinder.
D375A-6

10-141

DRAFT
Hydraulic system
Pin puller switch

Pin puller switch

Function
q The pin puller solenoid valve is controlled by
turning the pin puller switch ON/OFF. This
switches the oil circuit to the pin puller cylinder
and sets the shank mounting pin to the PUSH IN
or PULL OUT position.

10-142

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

D375A-6

DRAFT
Hydraulic system
Pin puller solenoid valve

Pin puller solenoid valve

1. Plug
2. Spring
3. Spring retainer
4. Valve body
5. Spool
6. Spring retainer
7. Spring
8. Push pin
9. Solenoid assembly

D375A-6

A: To pin puller cylinder bottom end


B: To pin puller cylinder head end
P: From power train pump
T: To steering case

10-143

DRAFT
Hydraulic system
Pin puller solenoid valve

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

10-144

2. Pin puller switch at PULL OUT position


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

D375A-6

Hydraulic system
Blade control lever (only for the machine with dual tilt specification)

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

1. Switch (Dual/single tilt selector)


2. Switch (pitch)
3. Cover
Outline
q The blade is raised, lowered, and tilted to the
right or left respectively by moving the blade control lever forward and backward or to the right or
left.Dual tilt operation can be performed by moving the lever to the right and left with switch (1)
set to the "DUAL" position.Pitch operation can
also be performed by moving the lever to the
right and left with switch (2) being pressed.
q When the lever is operated with switch (2) being
pressed, the blade pitches.When the lever is
moved to the left, the blade pitches backward,
and when moved to the right, the blade pitches
forward.
D375A-6
(06)

10-145

4. Connector (male)
5. Connector (female)

10-145
When the switch (1) is set to the "DUAL" position
and the lever is operated, the blade is dual tilted.When the lever is moved to the left, the blade
is dual tilted to the left. When the lever is moved
to the right, the blade is dual tilted to the right.
Even when switch (1) is set to either "DUAL" or
"SINGLE" position, if the lever is moved to the
right or left with the switch (2) kept pressed, the
blade pitches.

10-145

DRAFT
Hydraulic system
Work equipment pump

Work equipment pump


Type: HPV190
General view

10-146

D375A-6

DRAFT
Hydraulic system
Work equipment pump

Outline
q This pump consists of a variable displacement
swash plate type piston pump and LS valve.
PA: Pump discharge port
PB: Pump pressure inlet port
PD1: Case drain port
PD2: Drain plug
PEN: Control pressure pickup port
PLS: Load pressure inlet port
PLSC: Load pressure pickup port
PS: Pump suction port
1. Front pump
2. LS valve

D375A-6

10-147

DRAFT
Hydraulic system
Work equipment pump

Sectional view

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

10-148

D375A-6

DRAFT
Hydraulic system
Work equipment pump

Function
q The pump converts the engine rotation transmitted to its shaft to oil pressure and oil flow, corresponding to the load.
q It is possible to change the discharge amount by
changing the swash plate angle.

Structure
Cylinder block (7) is supported by shaft (1) on
splined area (12).
q Shaft (1) is supported by each bearing (13).
q Tip of piston (6) is concaved and shoe (5) is
crimped to it to form one unit.
q Piston (6) and shoe (5) constitute a spherical
bearing.
q Rocker cam (4) has flat surface (A), and shoe (5)
is always pressed against this surface while sliding in a circular pattern.
q Rocker cam (4) conducts high pressure oil to cylinder surface (2) with cradle (B), which is secured to the case, and forms a static pressure
bearing when it slides.

D375A-6

q
q

Piston (6) carries out relative movement in the


axial direction inside each cylinder chamber of
cylinder block (7).
Cylinder block (7) seals the pressurized oil to
valve plate (8) and carries out relative rotation.
This surface is designed so that the oil pressure
balance is maintained at a suitable level.
The oil inside the respective cylinder chambers
of cylinder block (7) is sucked and discharged
through valve plate (8).

10-149

DRAFT
Hydraulic system
Work equipment pump

Operation of pump
q Cylinder block (1) rotates together with shaft (7),
and shoe (5) slides on flat surface (A).
q Rocker cam (4) moves along cylindrical surface
(B), so angle (4) between center line (X) of rocker cam (7) and the axial direction of cylinder
block (a) changes.
q (a) is called the swash plate angle.

q
q

As center line (X) of rocker cam (4) matches the


axial direction of cylinder block (7) (swash plate
angle (a) = 0), the difference between volumes
(E) and (F) inside cylinder block (7) becomes 0.
Suction and discharge of pressurized oil is not
carried out in this state. Namely pumping action
is not performed. (Actually, however, the swash
plate angle is not set to 0)

With center line (X) of rocker cam (4) at a swash


plate angle (a) in relation to the axial direction of
cylinder block (7), flat surface (A) acts as a cam
in relation to shoe (5).
Piston (6) slides on the inside of cylinder block
(7), so a difference between volumes (E) and
((F) is created inside cylinder block (7).
A single piston (6) sucks and discharges the oil
by the amount (F) - (E).
As cylinder block (7) rotates and the volume of
chamber (E) becomes smaller, the pressurized
oil is discharged.
The volume of chamber (F) grows larger and, in
this process, the oil is sucked.

10-150

D375A-6

DRAFT
Hydraulic system
Work equipment pump

Control of delivery
q If the swash plate angle (a) becomes larger, the
difference between volumes (E) and (F) becomes larger and pump delivery (Q) increases.
q Servo piston (10) is used for changing swash
plate angle (a).
q Servo piston (10) carries out linear reciprocal
movement according to the signal pressure from
the PC and LS valves.
q This linear movement is transmitted to rocker
cam (4) through slider (14).
q Being supported by cradle (2) on the cylindrical
surface, rocker cam (4) pivots on the surface
while continuing revolving movement.
q The area of servo piston (10) for receiving the
pressure are not identical on the left side and
right side. Main pump discharge pressure (self
pressure) (PP) is always brought to the pressure
chamber of the small diameter piston side.
q Output pressure (PEN) of the LS valve is brought
to the pressure chamber of the large diameter
piston side.
q The movement of servo piston (10) is controled
by the relationship of pressure between small diameter piston side (PP) and large diameter side
(PEN) and by the ratio of the area receiving the
pressure between small diameter piston and
large diameter piston.

D375A-6

10-151

DRAFT
Hydraulic system
Work equipment pump

LS valve

PA: Pump port


PDP: Drain port
PLP:LS control pressure output port
PLS: LS pressure input port
PP: Pump port
PPL: Drain port
PSIG: Drain port

1. Sleeve
2. Piston
3. Spool
4. Spring
5. Sheet
6. Sleeve
7. Plug
8. Lock nut

Function
q The LS (load sensing) valve detects the load and
controls the pump delivery.
q This valve controls main pump delivery (Q) according to differential pressure (dPLS) [= (PP) (PLS)], called the LS differential pressure [the
difference between main pump discharge pressure (PP) and control valve outlet port pressure
(PLS)].
q Main pump discharge pressure (PP), pressure
(PLS) [called LS pressure] coming from the control valve output enter this valve.
q The relationship between LS differential pressure (dPLS) [= (PP) - (PLS)], which is a diffential
pressure between main pump discharge pressure (PP) and LS pressure (PLS) , and delivery
(Q) is as shown in the diagram.

10-152

D375A-6

DRAFT
Hydraulic system
Work equipment pump

Operation
When the control lever is operated to Neutral

q
q

q
q
q

The LS valve is a three-way selector valve, with


pressure (PLS) (LS pressure) from the inlet port
of the control valve brought to spring chamber
(B), and pump discharge pressure (PP) brought
to port (H) of sleeve (8)
Magnitude of the force resulting from this LS
pressure (PLS), force of spring (4) and the pump
discharge pressure (self pressure) (PP) determine the position of spool (6).
Before the engine is started, servo piston (10) is
pushed to the right. (See right drawing)
If the control lever is at the neutral position when
the engine is started, LS pressure (PLS) will be
set to 0 MPa {0 kg/cm2}. (It is interconnected to
the drain circuit via the control valve spool)
Spool (6) is pushed to the right, and port (C) and
port (D) will be connected.
Pump pressure (PP) is conducted to the larger
diameter end from the port (K).
The same pump pressure (PP) is conducted to
the smaller diameter end from the port (J).

D375A-6

According to the difference in the areas on servo


piston (10), the servo piston is moved in the direction which makes the swash plate angle minimum.

10-153

DRAFT
Hydraulic system
Work equipment pump

Mechanism to make the pump delivery maximum

q
q
q

When the difference between pump discharge


pressure (PP) and LS pressure (PLS), in other
words, LS differential pressure (dPLS) becomes
smaller [for example, when the area of opening
of the control valve becomes larger and pump
discharge pressure (PP) drops], spool (6) is
pushed to the left by the combined force of LS
pressure (PLS) and the force of spring (4).
When spool (6) moves, port (D) and port (E) are
interconnected and connected to the PC valve.
The pressure across circuits (D) and (K) becomes drain pressure (PT).
The pressure at the large piston diameter end of
servo piston (10) becomes drain pressure (PT)
and pump discharge pressure (PP) always is
conducted to the small diameter end port (J) so
servo piston (10) is pushed to the left, and
moves the swash plate in the direction to make
the delivery larger.

10-154

D375A-6

DRAFT
Hydraulic system
Work equipment pump

Mechanism to make the pump delivery minimum

When LS differential pressure (dPLS) becomes


larger [for example, when the area of opening of
the control valve becomes smaller and pump
pressure (PP) rises] because of the rightward
move (it reduces pump delivery) of servo piston
(10) , pump pressure (PP) pushes spool (6) to
the right.
The movement of spool (6) transmits pump discharge pressure (PP) to the large diameter end
of the piston through port (C) , port (D) and port
(K).
Pump pressure (PP) is also conducted to port (J)
of the small diameter end of the piston, but because of the difference in area between the large
diameter end and the small diameter end on servo piston (10), it is pushed to the right. As the result, the servo piston (10) moves into the
direction to make the swash plate angle smaller.

D375A-6

10-155

DRAFT
Hydraulic system
Work equipment pump

When servo piston is balanced

The symbols (A1), (A0) and (PEN) represent the


area receiving the pressure at the large diameter
end of the piston, the area receiving the pressure
at the small diameter end and the pressure conducted to the large diameter end of the piston,
respectively.
When the force generated by main pump pressure (PP) in the LS valve is balanced with the
combined force of spring (4) and LS pressure
(PLS) , and the relationship becomes (A0)
(PP) = (A1) (PEN), servo piston (10) is
stopped in that position.
The swash plate of the pump is held at the intermediate position. [Spool (6) is stopped at a position where the opening area from port (D) to port
(E) and the distance from port (C) to port (D) is
almost the same.]
The relationship between the area receiving the
pressure at both ends of servo piston (10) is (A0)
: (A1) = 3 : 5 so the pressure applied accross the
piston when it is balanced becomes (PP):(PEN)
C 5:3.

10-156

Force of spring (4) is adjusted in such that the


position of the balanced stop of this spool (6) is
determined when (PP) - (PLS) = 1.96 MPa
{20 kg/cm2} at the median of the specified value.

D375A-6

DRAFT
Hydraulic system
Work equipment pump

D375A-6

10-157

Hydraulic system
Control valve

Control valve
6-spool valve for dual tilt
General view

10-158

10-158
10-158
10-158

D375A-6
(04)

DRAFT
Hydraulic system
Control valve

A1: To blade lift cylinder head


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

D375A-6

10-159

DRAFT
Hydraulic system
Control valve

Sectional view (1/4)

1. Ripper tilt valve


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

10-160

D375A-6

DRAFT
Hydraulic system
Control valve

(2/4)

1. LS check valve
2. Preset plug

D375A-6

10-161

DRAFT
Hydraulic system
Control valve

(3/4)

1. Main relief valve


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

10-162

D375A-6

DRAFT
Hydraulic system
Control valve

(4/4)

1. Suction safety valve


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

D375A-6

10-163

Hydraulic system
Control valve

5-spool valve for single tilt


General view

10-164

10-164
10-164

D375A-6
(04)

Hydraulic system
Control valve

A1: To blade lift cylinder head


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

D375A-6
(04)

10-164-1

Hydraulic system
Control valve

Sectional view (1/4)

10-164-2

1. Ripper tilt valve


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

10-164-2

D375A-6
(04)

Hydraulic system
Control valve

(2/4)

10-164-3

1. LS check valve
2. Preset plug

D375A-6
(04)

10-164-3

Hydraulic system
Control valve

(3/4)

10-164-

1. Main relief valve


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

10-164-4

D375A-6
(04)

Hydraulic system
Control valve

(4/4)

10-164-5

1. Suction safety valve


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

D375A-6
(04)

10-164-5

Hydraulic system
Control valve

Operation of control valve

10-164-6

10-164-6
When the main spool is at the HOLD position, it
drains the excess oil discharged by the pump, and
prevents the pressure from being formed in the circuit from rising.
Operation
10-164-6
Function

When set to "HOLD" position (operation of unload


valve)
10-164-6
q

q
q

When the main spool is at the HOLD position,


the pump pressure passes from chamber (A)
through oriffice (4) to chamber (D). Chambers
(C) and (C') are connected to the drain circuit.
When oil is supplied from the pump, the pressure
in chamber (D) rises, and spool (1) is pushed to
the right by pressure (FO) which is determined
by the cross-sectional area of piston (3) receiving the pressure.
When (FO) becomes larger than set force (FS)
of spring (2), the spool moves to the right and
connects the passage between chamber (A) and
chamber (B), so the oil from the pump is drained.
Therefore, spool (1) is balanced at a position that
matches the supply of oil from the pump.
Actually, the amount of oil supplied from the
pump is small, so the pressure in the circuit is almost the same as the set force of spring (2).

10-164-6

D375A-6
(04)

Hydraulic system
Control valve

Control of flow rate

10-165

Work equipment valve

Use of the CLSS circuit (Closed - Center Load


Sensing System) makes it possible to control the oil
flow by adjusting the area of opening of the spool
driven by the PPC valve, regardless of the load.
When set to "HOLD" position (blade right tilt cylinder circuit on dual tilt specification machine)

When the spool is set to the "HOLD" position, the


pump pressure is sent from chamber (A) to pressure compensation valve spool (3) through its
notch, and then conducted through chamber (B)
to chamber (C).
The oil in chamber (G) is drained through chamber (H) to chamber (F).

D375A-6
(04)

10-165

When this happens, the pump pressure is acting


on the left end of spool (3) of the pressure compensation valve, so it pushes against the force of
spring (4) and moves rightward to the maximum
stroke position.
At this condition, the area of the opening for
spool (1) of the blade tilt valve is at its minimum.

10-165

Hydraulic system
Control valve

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

q
q

10-16

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


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

10-166

D375A-6
(04)

Hydraulic system
Control valve

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

When the tilt lever is operated to right tilt position, pilot pressure (PB1) acts on the right end of
spool (1) through the PPC valve.
when the pressure becomes greater than the set
force of spring (2), the spool (1) begins to move
leftward. It is balanced at a position corresponding to PPC output pressure (PB1.

D375A-6
(04)

q
q

10-16 -1

dPLS = differential pressure between ports


(L) and (K) = 1.96 {20 kg/cm2}
dPLS' = differential pressure between ports
(J) and (D)
dPLS C dPLS'

10-166-1

Hydraulic system
Control valve

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


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

10-166-2

D375A-6
(04)

Hydraulic system
Control valve

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

When the tilt lever is operated to right tilt position, pilot pressure (PB3) acts on the right end of
spool (1) through the PPC valve.
when the pressure becomes greater than the set
force of spring (2), the spool (1) begins to move
leftward. It is balanced at a position corresponding to PPC output pressure (PB3.

D375A-6
(04)

q
q

10-167

dPLS = differential pressure between ports


(K) and (J) = 1.96 {20 kg/cm2}
dPLS' = differential pressure between ports
(H) and (D)
dPLS C dPLS'

10-167

Hydraulic system
Control valve

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


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

10-168

D375A-6
(04)

Hydraulic system
Control valve

When set to relief (blade lift, blade tilt, ripper lift, ripper tilt)

a The diagram shows the condition when work equipment LS valve (5) is relieved at blade tilt stroke end.

q
q
q

dP1 = dP3 + dP4 = Differential pressure between ports (M) and (P)
dP2 = Differential pressure between ports (P)
and (N)
dP3 = Differential pressure between ports (M)
and (B)

D375A-6
(04)

q
q

10-169

dP4 = Differential pressure between ports (B)


and (P)
dLS = dP1 + dP2 = Differential pressure between ports (M) and (N) = 1.96 {20 kg/cm2}

10-169

Hydraulic system
Control valve

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


of tilt cylinder (8) becomes higher, work equipment LS relief valve (5) will open and oil will be
drained from LS circuit (O).
(Ports (P), (F), (G), (J) and (K))
As a result, there will be a drop in pressure in LS
passage (O) starting from LS sensing hole (F),
and (dP2) will become larger.
For the same reason, if the pressure in chamber
(I) and (H) drops, spool (2) will push against
spring (3) and move to the right, and will make
the opening between chambers (B) and (C)
smaller, so the flow between chambers (B) and
(C) will be throttled and (dP4) will become larger.
Because of the pump swash plate control, the
system circuit is balanced at a circuit pressure
which makes the pressure loss generated by the
flow at work equipment LS relief valve (5) (dP1)
+ (dP2) equal to LS differential pressure (dLS).
When this happens, pump LS valve (6) detects
the differential pressure generated by LS relief
valve (5), and moves the pump swash plate from
the maximum to the minimum position.
The swash plate is balanced at a position where
the LS differential pressure is 1.96 {20 kg/cm2}.
When the pump is at the minimum swash plate
angle (minimum oil flow), if the minimum oil flow
is greater than the LS relief oil flow + leakage at
any part, the pressure resides in the pump circuit
[the pump and chambers (A) and chamber (B)]
through pressure compensation valve (7), so the
differential pressure rises.
If this differential pressure goes above the set
pressure for unload valve (4), the unload valve is
actuated to relieve the excess oil flow and balance the circuit.

10-170

D375A-6
(04)

Hydraulic system
Control valve

Pitch system on dual tilt specification machine

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

In the single tilt mode, solenoid selector valve (1)


is in the neutral position and connected to (PA4)
and (PB4) of the control valve as shown in the
figure.
PPC circuits (2) and (3) are separated from output circuits (4) and (5) of the PPC valve.

D375A-6
(04)

10-171
10-171

As a result, the right tilt cylinder does not move


and only the left tilt cylinder moves to carry out
the single tilt operation.

10-171

Hydraulic system
Control valve

When dual tilt operation is carried out

10-172

In the dual tilt mode, the position of solenoid selector valve (1) is changed as shown in the figure.
At this time, PPC circuit (2) connected to (PB3)
of the control valve is connected to output circuit
(4) of the PPC valve.

10-172

PPC circuit (3) connected to (PA3) of the control


valve is connected to output circuit (5) of the
PPC valve.
Accordingly, both tilt cylinders move in the opposite directions each other to carry out the dual tilt
operation.

D375A-6
(04)

Hydraulic system
Control valve

When pitch operation is carried out

q
q

10-172-1

In the pitch mode, the position of solenoid selector valve (1) is changed as shown in the figure.
At this time, PPC circuit (2) connected to (PB3)
of the control valve is connected to output circuit
(5) of the PPC valve.

D375A-6
(04)

PPC circuit (3) connected to (PA3) of the control


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

10-172-1

Hydraulic system
Control valve

10-172-2

D375A-6
(04)

DRAFT
Hydraulic system
Self-pressure reducing valve

Self-pressure reducing valve


General view

P1: From fan pump


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

D375A-6

10-173

DRAFT
Hydraulic system
Self-pressure reducing valve

Sectional view

1. Valve (sequence valve)


2. Spring
3. Valve (pressure reducing valve)
4. Spring (pressure reducing valve main)
5. Filter

10-174

6. Screw
7. Poppet
8. Spring (for pressure reducing valve pilot)
9. Spring (safety valve)
10. Ball

D375A-6

DRAFT
Hydraulic system
Self-pressure reducing valve

Function
q

The self-pressure reducing valves reduce the


discharge pressure of the fan pump and supplies
it to the PPC valve, the EPC valve, etc. as the
control pressure.

D375A-6

10-175

DRAFT
Hydraulic system
Self-pressure reducing valve

Operation
At engine stop (both pressure are low)

q
q
q

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


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

10-176

D375A-6

DRAFT
Hydraulic system
Self-pressure reducing valve

When the load pressure (P2) is lower than the output pressure (PR) of the self pressure reducing valve

The force of spring (3) and the force of exerted


by the (PR) pressure [0MPa {0 kg/cm2} at the
time of engine stop] push valve (2) in the direction to block the passage between the ports (P1)
and (P2). When the hydraulic oil enters (P1) port,
the value balances at a position where the expression [Force exerted by pressure (P1) C
Force of spring (3) + Force (area (d) Pressure
(PR) ] holds, and the area of the opening between ports (P1) and (P2) is adjusted so that
pressure (P1) is maintained higher than pressure (PR) .
When the (PR) pressure rises above set pressure, the poppet (5) opens and the hydraulic oil
flows through the route, from (PR) port, through
hole (a) in the spool (8), through the opening of
the poppet (5) , through to the tank port (T).

D375A-6

Therefore, differential pressure is developed


across hole (a) in spool (8) to move spool (8) in
the direction to block the opening between ports
(P1) and (PR) . Thus this valve uses the area of
the opening to regulate pressure (P1) to a certain level (set pressure) and supplies it as pressure (PR).

10-177

DRAFT
Hydraulic system
Self-pressure reducing valve

When load pressure (P2) is high

When load pressure (P2) rises due to digging or


other operations, pump delivery increases and
pressure (P1) rises. When the expression {Force
exerted by pressure (P1) > Force of spring (3) +
Force [area (d) pressure (PR)]} holds, and
valve (2) moves downward to its stroke end. As
a result, the opening between the ports (P1) and
(P2) increases, the passage resistance becomes smaller to reduce engine horsepower
loss.
When pressure (PR) rises above the set pressure, poppet (5) opens and hydraulic oil flows
through the route, from port (PR) , through hole
(a) in spool (8), and the opening of poppet (5) to
the tank port (T).

10-178

Therefore, differential pressure is developed


across hole (a) in spool (8) to move spool (8) to
block the opening between ports (P1) and(PR) .
Thus this valve uses the area of the opening to
regulate pressure (P1) to a certain level (set
pressure) and supplies it as pressure (PR).

D375A-6

DRAFT
Hydraulic system
Self-pressure reducing valve

When abnormally high pressure is generated

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

D375A-6

10-179

DRAFT
Work equipment
Cylinder stay

Work equipment
Cylinder stay

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

10-180

D375A-6

DRAFT
Cab and its attachments
Cab mount

Cab and its attachments


Cab mount

1. Support
2. Damper mount (front)
3. Damper mount (rear)

D375A-6

Outline
q The cab mounts are installed at two places in the
front section and at two places in the rear section
of the floor frame to secure the cab to the floor
frame.
q Oil-filled cab mounts are used to absorb vibration.

10-181

DRAFT
Cab and its attachments
Cab

Cab
Cab assembly

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

10-182

D375A-6

DRAFT
Cab and its attachments
Cab

ROPS

1. ROPS

D375A-6

10-183

DRAFT
Electrical system
Engine control

Electrical system
Engine control

1. Decelerator pedal
2. Deceleration potentiometer
3. Starting switch
4. Work equipment controller
5. Power train controller
6. Fuel control dial
7. Battery
8. Circuit breaker
9. Battery relay
10. Starting motor
11. Engine controller
12. Alternator

10-184

Outline
q The throttle signal of the fuel control dial is input
to the power train controller and processed together with the other information, then the result
is sent as the throttle command to the engine
controller. The engine controller controls the fuel
supply pump according to the command.

D375A-6

DRAFT
Electrical system
Engine control system

Engine control system

Outline
q The engine throttle controller receives the fuel
control dial signal of the 1st throttle, decelerator
pedal signal of the 2nd throttle, and 3rd throttle
signal which is the control signal from the power
train controller, and then controls the fuel supply
pump according to the command signal having
the lowest engine speed.
The control signals of the 3rd throttle are as
follows.
1) Automatic-deceleration (F3, R3, F2, R2)
2) Neutral deceleration
3) Shoe slip control (if equipped)
q The power train controller calculates a proper
engine speed from information items (1), (2), etc.
and sends it as the 3rd throttle signal to the engine throttle controller.

D375A-6

The information of the engine controller is possessed jointly by the other controllers through
the network and used for the optimum control of
the engine and power train.
The automatic deceleration is a function of lowering the engine speed temporarily when the
travel direction is changed from F3, R3, F2 or R2
(for protection of the transmission clutch).

10-185

DRAFT
Electrical system
Engine control system

Engine controller

Outline
Engine controller mounted on engine
q Since the engine controller is mounted on the
engine, it is easy to be maintained.
q In order to secure the reliability of mounted engine controller, engine controller cooler is installed to cool the engine controller by fuel.
q Rubber vibration isolator reduces vibration.
Common engine controller
q The common engine controller CM850 is adopted which is co-developed by Komatsu and Cummins.

10-186

D375A-6

DRAFT
Electrical system
Engine control system

Meanings of signal classes in the terminal table


shown below are as follows.
A: Power supply
B: Input
C: Ground/Shield/Return
D: Output
E: Communication

Signal name
NC (*)

Pin No.

Signal name

Input/output

37

Sensor power source (5 V)

38

GND

39

NC (*)

40

NC (*)

41

NC (*)

Input/output

42

NC (*)

43

NC (*)

Boost pressure sensor

CN-CE01
Pin No.

CN-CE01

NC (*)

44

Ambient pressure sensor

45

Injector #1 (+)

Supply pump #1 (+)

46

Injector #5 (+)

Supply pump #1 ()

47

Sensor GND

CAN (-)

48

Ne sensor ()

NC (*)

49

NC (*)

CAN(+)

50

NC (*)

Supply pump #2 (+)

51

Injector #2 ()

10

Supply pump #2 ()

52

Injector #3 ()

11

EGR valve ()

53

Injector #1 ()

12

NC (*)

54

Injector #2 (+)

Injector #3 (+)

13

Engine oil pressure sensor

55

14

NC (*)

56

Injector #4 (+)

15

Coolant temperature sensor

57

Injector #6 (+)

16

Sensor power source (5 V)

58

Injector #4 ()

17

Engine oil temperature sensor

59

Injector #6 ()

18

NC (*)

60

Injector #5 ()

19

EGR valve position sensor

20

NC (*)

21

NC (*)

22

EGR valve (+)

23

Boost temperature sensor

24

NC (*)

25

Common rail pressure sensor

26

BKup sensor (+)

27

NE sensor (+)

28

NC (*)

29

Bypass valve position sensor

30

Fuel temperature sensor

31

Bypass valve (+)

32

NC (*)

33

Sensor power source (5 V)

34

NC (*)

35

NC (*)

36

NC (*)

D375A-6

*: Never connect to NC, or malfunctions or failures


will occur.

10-187

DRAFT
Electrical system
Engine control system

CN-CE02

CN-CE02
Pin No.

Signal name

Input/output

Pin No.

Signal name

Input/output

NC (*)

43

NC (*)

NC (*)

44

NC (*)

NC (*)

45

NC (*)

NC (*)

46

CAN(+)

NC (*)

47

CAN (-)

NC (*)

48

NC (*)

NC (*)

49

NC (*)

NC (*)

50

NC (*)

Decelerator signal

10

NC (*)

11

NC (*)

12

NC (*)

13

NC (*)

14

NC (*)

GND

15

NC (*)

Power source (+24 V constant)

16

NC (*)

Power source (+24 V constant)

17

NC (*)

18

NC (*)

19

NC (*)

20

NC (*)

21

NC (*)

22

Sensor power source (5 V)

23

GND

24

NC (*)

25

NC (*)

26

NC (*)

27

NC (*)

28

NC (*)

29

NC (*)

30

NC (*)

31

NC (*)

32

NC (*)

33

GND

34

NC (*)

35

NC (*)

36

NC (*)

37

CAN shield

38

NC (*)

39

Key switch (ACC)


Electrical intake air heater relay
(+)
NC (*)
Electrical intake air heater relay
return

40
41
42

10-188

*: Never connect to NC, or malfunctions or failures


will occure.
CN-CE03
Pin No.
1
GND

Signal name

Input/output
C

*: Never connect to NC, or malfunctions or failures


will occur.

D
C

D375A-6

DRAFT
Electrical system
Engine control system

Sensors
Fuel temperature sensor
q The fuel temperature sensor senses the fuel
temperature and sends it to the engine controller. The sensor unit is a thermistor the resistance
of which changes according to the temperature.
q The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.

D375A-6

10-189

Electrical system
Engine control system

EGR valve position sensor


This sensor senses the opening and closing positions of the EGR valve.

10-20

1. EGR valve position sensor


The following graph shows the output characteristics of the position sensor.

10-190

D375A-6
(06)

DRAFT
Electrical system
Engine control system

NE speed sensor (Crank angle sensor)


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

Bkup speed sensor (G sensor)


(Cylinder No. sensor)
q Similarly to the NE speed sensor, this sensor utilizes the pulses of 0 5 generated by the change
of the magnetic line crossing the sensor unit.
q The disc gear installed to the central part of the
camshaft of the high-pressure pump has teeth
(cut parts) around it at intervals of 60 .
q In addition to the above teeth, one more tooth is
installed. Accordingly, 7 pulses are generated
every 2 revolutions of the engine.
q The standard pulse of the No. 1 cylinder is recognized by the combination of the NE speed
sensor pulse and Bkup speed sensor pulse.

Ambient pressure sensor


This sensor is used to correct altitude.

Oil pressure sensor

D375A-6

10-191

DRAFT
Electrical system
Engine control system

Boost temperature sensor


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

10-192

Coolant temperature sensor


q The coolant temperature sensor senses the
coolant temperature and sends it to the engine
controller.
q The sensor unit is a thermistor the resistance of
which changes according to the temperature.
The engine controller applies voltage to the
thermistor and senses the temperature by the
voltage divided by the resistance in the computer and the resistance of the thermistor.

D375A-6

DRAFT
Electrical system
Engine control system

Deceleration potentiometer

1. Connector
2. Lever
3. Body
4. Potentiometer
5. Coupling
6. Shaft
7. Stopper

D375A-6

Outline
q The deceleration potentiometer is installed to the
front lower part of the operator's cab and connected to the decelerator pedal by linkage.
q

When the decelerator pedal is depressed, the


throttle potentiometer shaft is rotated by the linkage and the potentiometer resistance changes.
Constant voltage is applied between pins (A)
and (C) of the potentiometer and an electric
signal is sent through pin (B) to the engine
controller according to the position of the decelerator pedal.

10-193

DRAFT
Electrical system
CRI engine control system

CRI engine control system


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

10-194

D375A-6

Electrical system
CRI engine control system

1. NE speed sensor
2. Engine throttle controller
3. Injector assembly
3A. Orifice
3B. Control chamber
3C. Hydraulic piston
3D. Injector
3E. Nozzle
4. Orifice (for air bleeding)
5. Fuel tank
6. Pre fuel filter
7. Main fuel filter
8. Overflow valve
9. Fuel supply pump
9A. PCV
9B. High pressure pump
9C. Priming pump
9D. Feed pump
9E. Bkup speed sensor (G sensor)
10. Common rail
11. High pressure injection pipe
12. Flow damper
13. Pressure limiter
14. Electric priming pump
15. Engine throttle controller cooler
10-205
Outline
q The signals detected by various sensors are input to the engine controller.
q The engine controller processes input signals
and output command signals to each actuator to
control the fuel injection rate and fuel injection
timing.

D375A-6
(06)

10-205
System configuration
q The CRI system consists of fuel supply pump
(9), common rail (10), injectors (3), engine throttle controller (2) to control them, and sensors.
q The fuel supply pump generates fuel pressure in
the common rail. The fuel pressure is controlled
by the fuel delivery from the supply pump. The
discharge rate is controlled by turning on and off
PCV (discharge control valve) (9A) of the fuel
supply pump according to the electric signals
from the engine throttle controller.
The common rail receives the pressurized fuel
from the fuel supply pump and distributes it to
the cylinders.
The fuel pressure is sensed by the common rail
fuel pressure sensor installed to the common rail
and controlled by the feedback method so that
the actual fuel pressure corresponds to the
command pressure set according to the engine
speed and the load on the engine.
The fuel pressure in the common rail is applied
to the nozzle (3E) and control chamber (3B) of
the injector through the high-pressure fuel pipe
of each cylinder.
q The injector controls the fuel injection rate and
fuel injection timing by energizing and de-energizing the TWV (2-way solenoid valve). If the
TWV is energized, the fuel circuit is so changed
that the high-pressure fuel in the control chamber flows out through orifice (3A). As the result,
the force exerted by the pressure of the
high-pressure fuel on the nozzle side raises the
needle valve to start fuel injection. If the TWV is
de-energized, the fuel circuit is so changed that
the pressure of the fuel applies to the control
chamber through the orifice. As a result, the needle valve lowers and finishes fuel injection. Accordingly, the fuel injection timing and fuel
injection rate are controlled respectively by the
timing to energize the TWV and the duration of
energizing the TWV.

10-195

DRAFT
Electrical system
Monitor system

Monitor system

The monitor system monitors the machine condition with the sensors installed to various parts
of the machine and processes and displays the
obtained information on the monitor panel quickly to notify the operator of the machine condition.
The main display sections and functions of the
panel are as follows.

1. Monitor unit which turns on the alarm when the


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

The CPU (Central Processing Unit) in the monitor panel displays and outputs various information processed by the power train controller. The
display unit is LCD (Liquid Crystal Display)

10-196

D375A-6

Electrical system
Monitor system

Processing on machine monitor (common to all specifications)


Display of machine monitoer
Contents and conditions of processing
1. Display of travel direction and gear speed.
q F1, R3, etc. are notified by CAN according to information of power train
controller.
2. Display of gauges of fuel level, engine coolant temperature, etc.
q Controller converts the sensor signals into gauge numbers and sends
them to the machine monitor by CAN.
3. Display of problem
q When the machine has a trouble, the corresponding failure code is notified to the machine monitor through CAN signal.
q The command to sound the buzzer or to light up the caution lamp is notified, too.
1) In standard screen
Action code, failure code
2) In abnormality record screen
The failure code (6-digit code) and the following items are displayed
q SMR at first occurrence
q SMR at latest occurrence
q Number of past occurrences
Display of monitoring condition
Contents and conditions of processing
1. The communication conditions of each sensor, each solenoid, and CAN
are displayed.
q The item Nos. and device conditions are notified to the machine monitor
by CAN.
q The machine monitor displays the items and each value.
2. Each items is selected by using the cursor switches and confirmation
switch.

10-197

Method

Flow of signals

CAN

CAN
Each sensor, solenoid
O
Controller
O
Machine monitor
CAN

Method

CAN

CAN

Flow of signals
Each sensor
O
Controller
O
Machine monitor

Other items
Contents and conditions of processing
1. Monitoring
2. Abnormality record
3. Maintenance record
4. Maintenance mode change
5. Phone number setting
6. Default
7. Adjustment
8. PM clinic
9. Cylinder cutout mode operation
10. No injection cranking
11. Fuel consumption display
12. Load memory display
13. VHMS setting
14. Snap shot
86. Setting of shoe slip control (if equipped)
87. Setting of pre-lubrication
88. Screen adjustment a

Method

Flow of signals

a Since this item is included in the service menu, it is not usually displayed.For details of the operating method, see "Special functions of monitor panel (EMMS)" section of Testing and adjusting.

D375A-6
(04)

10-197

DRAFT
Electrical system
Machine monitor

Machine monitor

Outline
q The machine monitor has the display function,
mode selection function and switch function for
electrical parts.
q The machine monitor has a CPU (Central Processing Unit) in it to process, display, and output
the information.
q The monitor display employs an LCD (Liquid
Crystal Display). The switches are flat sheet
switches.

10-198

Precautions on the machine monitor display


q The liquid crystal display panel may have black
spots (which do not light up) or bright spots
(which stay on). Products having 10 or less black
or bright spots conform the product specification;
such the condition is quite normal.
q When the engine is started, the battery voltage
may suddenly drop depending on the temperature and the battery condition. If this happens,
the display on the machine monitor may momentarily go out, but this does not indicate any abnormality.
q Continuous operation of the machine monitor
may display blue bright spots on the screen having a black background; it is quite normal.
The screen normally displayed on the monitor
has a blue or white background. For this reason,
blue spots will not cause any problem (since the
liquid crystal lights up red, blue, and green spots
when displaying white).

D375A-6

DRAFT
Electrical system
Machine monitor

Input and output signals


CN-CM01
Pin No.

CN-CM03
Signal name

1
2
3
4

Battery power (+24 V constant)


Battery power (+24 V constant)
Battery power GND
Battery power GND

Wake-up

6
7
8
9
10
11
12
13
14
15
16
17
18

Relay output
Chassis signal GND
Hydraulic oil pressure
Fuel level
NC (*)
Battery charge
Chassis analog signal GND
Light switch
Key switch (ACC)
Key switch (C)
Preheating
NC (*)
NC (*)

Input/out
put
Input
Input
Input/out
put
Output
Input
Input
Input
Input
Input
Input
-

*: Never connect to NC, or malfunctions or failures


will occur.
CN-CM02
Pin No.

Signal name

1
2
3
4
5
6
7
8

NC (*)
NC (*)
Coolant level sensor
NC (*)
NC (*)
NC (*)
Chassis signal GND
CAN terminating resistance

COMM_CAN_H_0

10

COMM_CAN_L_0

11
12

NC (*)
NC (*)

Input/out
put
Input
Input/out
put
Input/out
put
-

*: Never connect to NC, or malfunctions or failures


will occur.

Pin No.

Signal name

1
2
3

RS232C CD for communication terminal


RS232C RXD for communication terminal
RS232C SG for communication terminal
GND for communication terminal control signal
Communication terminal selection signal
RS232C RTS for communication terminal
RS232C TXD for communication terminal
RS232C DTR for communication terminal
RS232C DSR for communication terminal
RS232C CTS for communication terminal
RS232C RI for communication terminal
GND for communication terminal power
Input CH1 for communication terminal status
Output for communication terminal power
control
Output CH1 for communication terminal control
Output CH2 for communication terminal control
Input CH2 for communication terminal status
Power supply for communication terminal

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18

Input/out
put
Input
Input
Input
Output
Output
Output
Input
Input
Input
Input
Output
Output
Output
Input
Output

CN-CM04
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12

Signal name
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)
NC (*)

Input/out
put
-

*: Never connect to NC, or malfunctions or failures


will occur.
CN-CM05
Pin No.
1
2
3
4
5
6
7
8

D375A-6

Signal name
Power supply for camera
Camera NTSC signal input 1
Camera NTSC signal input 2
Camera NTSC signal input 3
Electric power supply GND for camera
Camera signal GND1
Camera signal GND2
Camera signal GND3

Input/out
put
Output
Input
Input
Input
-

10-199

DRAFT
Electrical system
Machine monitor

Monitor control portion

1. Gearshift mode selector switch


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

10-200

9. Fuel level gauge


10. Gearshift mode and preset gearshift pattern
11. Guidance icon
12. Function switch
13. Customization switch
14. Customization memory switch

D375A-6

Electrical system
Machine monitor

Machine monitor display


Display
category

Symbol

10-201
Display item

Contents

Radiator coolant level Below "low" line

Check

Oil pressure

D375A-6
(04)

Description
Displays when engine is stopped and
starting switch is set to ON position
Display when normal: OFF
Display when abnormal: ON

When sensor is abnormal or


Display when normal: OFF
when wiring harness is disDisplay when abnormal: ON
connected

Battery charge condiWhen charge is defective


tion

Engine oil level (if


equipped)

Lights up at low level or


below

Hydraulic oil level (if


equipped)

Lights up when oil level is


below suction limit

Displays when starting switch is set to


ON position and engine is running
Display when normal: OFF
Display when abnormal: ON CAUTION lamp flashes
Displays when starting switch is
turned to ON position with engine
stopped.
Display when abnormal: OFF Display
when normal: ON
Displays when starting switch is
turned to ON position with engine
stopped.
Display when normal: ON Display
when abnormal: OFF

10-201

Electrical system
Machine monitor

Display
category

Symbol

Display item

Oil pressure

Contents

Description

Lights when it becomes 49.0


kPa {0.5 kg/cm2} and below

Lights when it becomes 7.8 V


Battery charge condiand below while engine is
tion
running

Radiator coolant level

Cautions

Engine coolant temperature

Torque converter oil


temperature

Lights when it becomes


below "low" line

Engine coolant temperature


When highest gauge segment is;
Above 102 C: Symbol ON
Above 105 C: Symbol ON +
buzzer sounds
Torque converter oil temperature
When highest gauge segment is;
Above 120 C: Symbol ON
Above 130 C: Symbol ON +
buzzer sounds

Displays when starting switch is set to


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

Pilot

Above 100 C: Symbol ON


Hydraulic oil temperaAbove 110 C: Symbol ON +
ture
buzzer sounds

10-202

Maintenance

Lights up for 30 seconds


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

Air cleaner clogging

Lights up when -7,470 490


Pa {-762 50 mmH2O} is
reached.

Hydraulic oil level (if


equipped)

Lights up when oil level is


below suction limit

Preheating

When preheating

Lights according to required time


determined by engine controller.
It also lights up at the time of manual
preheat by setting the starting switch
at the preheat position (turning the
switch counterclockwise).

D375A-6
(04)

Electrical system
Machine monitor

Display
category

Symbol

Display item

Contents

Description

Engine coolant temperature

Reads the temperature

Gauge

Torque converter oil


temperature

Hydraulic oil temperature

D375A-6
(04)

Fuel level

Reads the level

Service meter (Hours


From 0 to 99999
meter)

Progresses when the engine is running

10-203

Electrical system
Machine monitor

10-204

Gauge

The gauge pointer disappears when information on coolant temperature or hydraulic oil temperature cannot
be obtained due to disconnection of CAN.
Gauge
Engine coolant temperature
(C)

Power train oil temperature


(C)

Hydraulic oil temperature


(C)

Fuel level
(l)

10-204

Range
A1
A2
A3
A4
A5
A6
B1
B2
B3
B4
B5
B6
C1
C2
C3
C4
C5
C6
D1
D2
D3
D4
D5
D6

Temperature or volume
105
102
100
85
60
30
130
120
118
90
50
0
110
100
98
70
20
0
1000
755
550
395
275
145

Indicator
Red
Red
Off
Off
Off
White
Red
Red
Off
Off
Off
White
Red
Red
Off
Off
Off
White
Off
Off
Off
Off
Off
Red

Buzzer sounds.

D375A-6
(04)

Electrical system
Machine monitor

10-205

Machine speed

1. 0 km/h
2. 5 km/h

3. 10 km/h
4. 15 km/h

1. 0 MPa
2. 10 MPa
3. 20 MPa

10-205

D375A-6
(04)

4. 0.4 MPa
5. 0.5 MPa
6. 0.7 MPa

4. 25 V
5. 30 V
6. 31 V

10-205

Engine speed

1. 500 rpm
2. 1000 rpm
3. 1500 rpm

4. 30 MPa
5. 40 MPa
6. 50 MPa

Engine oil pressure

1. 0 MPa
2. 0.2 MPa
3. 0.3 MPa

1. 0 V
2. 17 V
3. 20 V

10-205

Hydraulic pump oil pressure

10-205

Battery voltage

4. 2000 rpm
5. 2500 rpm
6. 3000 rpm

10-205

Drawbar pull

1. 0 W
2. 0.2 W
3. 0.4 W

4. 0.6 W
5. 0.8 W
6. 1.0 W

10-205

Electrical system
Machine monitor

10-206
Guidance icon and function switch
The function of the function switches differ depending on the screen display. Each guidance icon shows the
function of the switch below it.
Switches with no guidance icon are disabled.
The functions shown by the guidance icons are as shown in the table below.
Symbol

10-206

Switch
power

Item

Function

F6

Enter

Enters selected/set item.

F5

Return

Returns to previous screen or condition.

F4

Select service meter/clock

Switches service meter and clock display alternatively.

F5

Selection of maintenance
screen

Switches to Maintenance List screen.

F6

Select user mode screen

Switches to Use Menu screen.

F3

Select item

Selects item on left side (Selects right end item after left end
item).

F4

Select item

Selects item on right side (Selects left end item after right end
item).

F3

Select item

Selects item on lower side (Selects top item after bottom


item)/Resets holding of monitoring.

F4

Select item

Selects item on upper side (Selects bottom item after top


item)/Holds monitoring.

F1

Select item

Displays next page for selection (Selects top page after last
page).

F2

Select item

Displays previous page for selection (Selects last page after


top page).

F2

Return to default setting

Returns selected item to default setting. (Used for screen


adjustment.)

F1

Start

Starts operation. (Used to start measurement of split fuel consumption on fuel consumption display screen.)

F1

Stop

Stops operation. (Used to stop measurement of split fuel consumption on fuel consumption display screen.)

F1/F2

Clear

Clears selected / displayed item

F1

Set

Executes setting

F2

Change of multi-gauge

Changes display item for multi gauge

D375A-6
(04)

Electrical system
Machine monitor

Service meter and clock switching function10-207


Pressing F4 on the standard screen when the service meter is displayed in the top center of the
screen switches the display to the clock, and doing
so when the clock is displayed switches the display
to the service meter.

Maintenance reminder function

10-207
Pressing F5 on the standard screen switches to the
Maintenance List screen.

F1: Displays the next page.


Displays the top page when the last page is displayed.
F2: Displays the previous page.
Displays the last page when the top page is displayed.
F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Returns to the standard screen.
F6: Hold down the button to switch to the Maintenance Time Reset screen.
No operation at least 30 sec.: Returns to the standard screen.
q On the Maintenance List screen, if the time remaining until maintenance for any item is less
than thirty hours, the remaining time display is
highlighted in yellow. If the time remaining until
maintenance becomes 0 hours, the remaining
time display is highlighted in red.
q On the Maintenance Time Reset screen, the remaining time for the selected item can be reset
and returned to the default.

D375A-6
(04)

10-207

Electrical system
Machine monitor

F5: Cancels the reset to return to the Maintenance


List screen.
F6: Resets the remaining time and returns to the
standard screen.
No operation at least 30 sec.: Returns to the standard screen.
q

The defailt password is 000000.


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

q
q

The table below shows the maintenance items


and replacement intervals.
The time remaining to maintenance is reduced
as the machine is operated.

No.
01
02
03
41
04
07
08
10
19
20

Item
Engine oil
Engine oil filter
Fuel main filter
Fuel pre-filter
Hydraulic oil filter
Damper case oil
Finaldrive case oil
Hydraulic oil
P/L oil
P/L oil filter

Replacement interval
(Hours)
500
500
500
500
2000
2000
2000
2000
1000
500

P/L: Power train


q

The display of the maintenance monitor differs


according to the remaining time. The relationship is as shown in the table below.
Display

Condition
Remaining time for maintenance
Not displayed
for all items is more than 30
hours.
Notice display (black There is one or more items with
symbol on yellow less than 30-hour remaining time
background)
for maintenance.
There is one or more items with
Warning display
(white symbol on red less than 0-hour remaining time
for maintenance.
background)
q

To prevent careless reset of the maintenance interval, the screen is password protected.

10-208

D375A-6
(04)

Electrical system
Machine monitor

User mode
q
q

10-209
Pressing F6 on the standard screen enters the
user mode, switching to the User Menu screen.
In user mode, you can perform setting for items
relating to the machine monitor and machine
shown below.
Utility screen select
Multi-gauge
Screen adjustment
Time adjustment
Language setting
Reverse-interlok Enabled Mode (When camera is set)
Fan reverse mode
Skipping pre-lubrication

Normal
q

10-209

The standard screen is displayed.


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

Load display
q

10-209
The horizontal axis indicates the time and the
vertical axis indicates the pitch angle of the body.
The graph on the screen is updated and scrolled
to the left at intervals of several seconds.

Body pitch display


q
q

F3: Selects (highlights) an item one down.


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

Utility screen select


q

D375A-6
(04)

10-209
On this screen, the display item assigned to the
gauge at the center can be selected.

Multi gauge select


q

10-209

Electrical system
Machine monitor

Select desired item with switch F3 or F4 and enter that item with switch F6.

The following items can be selected.

Sellectable item for multi gauge


No.
Selected item
Remarks
1 PL oil temperature
With caution
Hydraulic oil tempera2
With caution
ture
3 Vehicle speed
Hydraulic pump pres4
sure
5 Engine oil pressure
With caution
6 Battery voltage
7 Engine speed
8 Traction force
9 Clock
Engine coolant temper10
For Utility Screen Select
ature
11 Fuel level
For Utility Screen Select

10-210
Selecting the Screen Adjustment on the User
Menu screen and pressing F6 switches to the
Screen Adjustment screen.
From this menu, you can adjust the brightness,
contrast, and luminance of the machine monitor
screen.
When the light switch is set to "Night mode ON",
the night mode screen is adjustable.
When the light switch is set to "Daytime mode
ON" or OFF, the daytime mode screen is adjustable.

Screen adjustment
q

q
q

F2: Returns all adjusted values to the defaults.


F3: Decreases the value indicated by the indicator
one graduation left.
F4: Increases the value indicated by the indicator
one graduation right.
F5: Cancels changes you made before entering
them with F6 and returns to the User Menu screen.
F6: Enter the changes and moves to the next item.
q For machines equipped with a camera, the
brightness, contrast, and illuminance of the camera screen are also adjustable.
q Select Screen Adjustment from the User Menu
screen to switch to the screen for selecting a
camera screen you want to adjust.

F3: Selects (highlights) an item one down.


F4: Selects (highlights) an item one up.
F5: Cancels changes you made before entering
them with F6 and returns to the User Menu screen.
F6: Moves to the setup screen of the selected (highlighted) item.
q The adjustment methods for the camera screen
and standard screen are the same.
q The background when adjusting the camera
screen is the No.1 camera image.

F3: Selects (highlights) an item one down.


F4: Selects (highlights) an item one up.
F5: Cancels changes you made before entering
them with F6 and returns to the User Menu screen.
F6: Enter the changes and moves to the next item.

10-210

D375A-6
(04)

Electrical system
Machine monitor

10-21
Select the Clock Adjustment on the User Menu
screen and press F6 to switch to the Clock Adjustment screen.
On this screen, you can change the setting of the
time displayed on the standard screen.

F5: Cancels change you made before


entering them with F6 and returns to the User
Menu screen.
F6: Enters the changes and moves to the
Time setting.

Clock adjustment
q

a Summer time (daylight saving time) is a


system to lead a life according to the
one-hour advanced time in order to make
efficient use of daylight time.
10-21
Select the Language on the User Menu screen
and press F6 to switch to the Language setting
screen.
From this menu, you can change the language to
be displayed on the monitor. Available languages are as follows.
English, Japanese, Chinese, French, Spanish,
Portuguese, Italian, German, Russian, and
Turkish

Language setting
q

1) Time setting
Adjust the clock time. If the item of Time is
not highlighted, press F6 to highlight it.
The hour display part is highlighted.
F3: Advances the hour display one hour.
F4: Sets the hour display back one hour.
F5: Cancels change you made before
entering it with F6 and returns to the User
Menu screen.
F6: Enters the change and moves to minute
setting.
The minute display part is highlighted.
F3: Advances the minute display one
minutes.
F4: Set the minute display back one minutes.
F5: Cancels the change you made before
entering it with F6 and returns to the User
Menu screen.
F6: Enters the change and moves to the
12/24 Mode setting.

F3: Selects (highlights) an item one down.


F4: Selects (highlights) an item one up.
F5: Cancels the change and returns to the User
Menu screen.
F6: Enters the change to return to the User Menu
screen.

2) 12h/24h Mode
Specify 12-hour clock (AM/PM) or 24-hour
clock for time display. If the item of "12h/24h
Mode " is not highlighted, press F6 to highlight it.
F3: Moves to the item one right.
F4: Moves to the item one left.
F5: Cancels the change you made and
returns to the User Menu screen.
F6: Enter the change and moves to Daylight
Saving Time setting.
3) Daylight Saving Time
Selecting ON for this sets the time forward 1
hour. Setting OFF returns to the ordinary
time.
F3: Moves to the item one right.
F4: Moves to the item one left.

D375A-6
(04)

10-211

Electrical system
Machine monitor

Setting of camera for reverse-interlock enabled mode


(applied to machines equipped with rear view camera)
10-212

When reversing the machine, the image of rear


view camera can be displayed on the multi monitor.
q Turn "ON" the starting switch, select "Pre-lubrication Skip Mode" on the screen (A) with F3 or
F4 key, then fix it with F6 key.
q Select "camera 1 or 2, 3, 1+2" with F3 or F4 key
while the screen (B) is displayed.
a If the connected camera is only one, "camera 1"
is only displayed on the menu.
q The selected camera is set by pushing F6 key,
and return to the screen (A).
q When shifting the travel lever to reverse, the
multi display switches to a view from camera
(screen (C) o(D))
q

Function of the function keys


F3: Selects (highlights) an item one down.
F4: Selects (highlights) an item one up.
F5: Return to former screen.
F6: Fix the selection.

a The setting whether cameras are installed or not


can be done on the service menu.
Only the cameras set on the service menu are
available.
a This function is still available even though the
mode is terminated.
a While the view from camera is displayed, travel/work equipment lock monitor is displayed on
the upper left of the screen (a), gear speed and
gearshift working mode etc. are displayed under
right of the screen (b) (screen (D)).
a The view range of camera is limited. Watch out
rear side carefully when traveling reverse.
a For safe reverse traveling, be careful to check
the rear side by using brake and deceleration
pedal.

10-212

D375A-6
(04)

Electrical system
Machine monitor

10-213
In this mode, the fan can be set to drive in reverse to clean the radiator core.
While the starting switch is set to OFF, select the
menu with switch F3 or F4 and enter it with
switch F6.
While screen (A) is displayed, press switch F6,
and the fan is ready to run in reverse.
While screen (B) is displayed, start the engine.

Fan reverse mode


q
q

q
q

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

Precautions for using fan reverse mode


q
q
q
q
q

D375A-6
(04)

10-213

Electrical system
Machine monitor

Pre-lubrication skip mode (applied to machines


equipped with pre-lubrication)
q
q

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

Function of checking service meter


q

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

When these switches are released, the LCD


goes out.
a Continuous operation of the machine monitor
may display blue bright spots on this screen; it is
quite normal.

10-214

D375A-6
(04)

Electrical system
Machine monitor

Function of checking display LCD


q

10-214-1
Continuously pressing the buzzer cancel switch
(1) and F2 at the same time on the standard
screen causes all the LCD elements to light in
white. Release F2 and buzzer cancel switch in
order.
One of the features of liquid crystal display panel
is that there may be black spots (spots that do
not light up) or white spots (spots that stay lit up)
on the screen. If there are fewer than ten black
or white spots, the monitor is normal.

Pressing any function switch returns to the previous screen.

D375A-6
(04)

10-214-1

Electrical system
Machine monitor

10-214-2

D375A-6
(04)

DRAFT
Electrical system
Lamp system

Lamp system
Operation

Relate electric circuit diagram

D375A-6

10-215

DRAFT
Electrical system
Engine preheat (electrical intake air heater) control

Engine preheat (electrical intake air heater) control


Operation

Relate electric circuit diagram

10-216

D375A-6

DRAFT
Electrical system
Palm command control system

Palm command control system

1. Machine monitor (Multi-information)


2. Gearshift mode switch
3. Engine controller
4. Power train controller
5. Engine speed sensor
6. Transmission control valve
7. Steering control valve
8. Transmission output shaft speed sensor

D375A-6

10-217

DRAFT
Electrical system
Palm command control system

Gearshift mode function


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

6. Preset gearshift pattern(gear speed at start)


7. Mark of "Dozing 2" (which indicates manual
gearshift mode)
C:Shoe slip control mode (if equipped)
8. Gear speed used currently
9. Preset gearshift pattern (gear speed at start)
10. Mark of "Ripping "(which indicates shoe slip
control mode)

Gear shift operation


q Select a gear by pressing (a) or (b) on the PCCS
lever (steering / directional / gearshift lever).
(a): Shift-up switch
(b): Shift-down switch

Display of screen
The gearshift mode is displayed in the gearshift
mode display section of the monitor panel as shown
below.
A: Auto gearshift mode
1. Gear speed used currently
2. Preset gearshift pattern (gear speed at start)
or maximum usable gear speed
3. Mark of AUTO (which indicates auto gearshift
mode)
4. Mark of "Dozing 1" (which indicates automatic
gearshift mode)
B: Manual gearshift mode
5. Gear speed used currently
10-218

D375A-6

DRAFT
Electrical system
Palm command control system

Setting preset gearshift pattern by using gearshift switches with travel control lever in neutral
q Set the preset gearshift pattern (gear speed at
start) or the maximum usable gear speed (for
only the auto gearshift mode) by using the gearshift switches with travel control lever in neutral.
A: Auto gearshift mode
Setting preset gearshift pattern (gear speed at
start) or maximum usable gear speed

B: Manual gearshift mode


Setting preset gearshift pattern (gear speed at
start)

C:Shoe slip control mode (if equipped)


Setting preset gearshift pattern (gear speed at
start)

D375A-6

a When the starting switch is set to ON position,


the auto gearshift mode ([F1 R1]) is set. When
the gearshift mode is changed, [F1 R1] is selected initially.
Changing gear speed by using gearshift switches during travel
q The maximum usable gear speed (in the auto
gearshift mode) or the current gear speed (in the
manual gearshift mode) can be changed with the
gearshift switches while the machine is traveling.
A: Auto gearshift mode
Changing maximum usable gear speed
During forward travel: The maximum usable
gear speed can be set to F1 - F2.
During reverse travel: The maximum usable
gear speed can be set to R1 R3.
Shift-up switch: Each time this switch is pressed,
the maximum usable gear speed is shifted up to
the next range.
Shift-down switch: Each time this switch is
pressed, the maximum usable gear speed is
shifted down to the next range.
B: Manual gearshift mode
Changing current gear speed
During forward travel: The current gear speed
can be set to F1 - F2.
During reverse travel: The current gear speed
can be set to R1 - R2.
Shift-up switch: Each time this switch is pressed,
the current gear speed is shifted up to the next
range.
Shift-down switch: Each time this switch is
pressed, the current gear speed is shifted down
to the next range.
C: Shoe slip control mode(if equipped)
Changing current speed
During forward travel: The current gear speed is
fixed to F1.
During reverse travel: The current gear speed
can be set to R1 - R2.
Shift-up switch: Each time this switch is pressed,
the current gear speed is shifted up to the next
range.
Shift-down switch: Each time this switch is
pressed, the current gear speed is shifted down
to the next range.

10-219

Electrical system
Sensor

Sensor

10-2 0

Sensor name

Type of sensor

When normal

When abnormal

Torque converter oil temperature


sensor

Resistive

Hydraulic oil temperature sensor

Resistive

Coolant level sensor

Contact

ON (Closed)

OFF (Open)

Fuel level sensor

Resistive

Transmission output shaft R speed


sensor

Resistive

Pitch angle sensor

Resistive

Acceleration sensor

Resistive

Speed sensor

Resistance

Engine oil level sensor

Contact

ON (Closed)

OFF (Open)

Air cleaner clogging sensor

Contact

OFF (Closed)

ON (Open)

Hydraulic oil level sensor

Contact

OFF (Closed)

ON (Open)

Torque converter oil temperature sensor


Hydraulic oil temperature sensor

1. Thermistor
2. Body
3. Tube

10-220

10-2 0
10-2 0

4. Tube
5. Wire
6. Connector

D375A-6
(04)

DRAFT
Electrical system
Sensor

Radiator coolant level sensor

1. Float
2. Sensor
3. Tube

4. Wire
5. Connector

Fuel level sensor

1. Connector
2. Float
3. Arm
4. Body
5. Spring
6. Contact
7. Spacer

D375A-6

Function
q The fuel level sensor is installed to the side face
of the fuel tank. The float moves up and down
according to the fuel level. This movement of the
float is transmitted by the arm to the variable resistor to change its resistance. This sends a signal to the monitor panel to indicate the remaining
fuel level. When the display on the monitor panel
reaches a certain level, a warning lamp flashes.

10-221

DRAFT
Electrical system
Sensor

Transmission output shaft speed sensor

1. Magnet
2. Terminal
3. Case
4. Boot
5. Connector
Pitch angle sensor

1. Body
2. Tube
3. Wire
4. Connector

10-222

D375A-6

DRAFT
Electrical system
Sensor

Acceleration sensor

1. Sensor portion
2. Wire
3. Connector
Outline
q The acceleration sensor is installed under the
front of the operator's cab.
q The position of the ball inside the sensor changes according to the acceleration.
The coil inside the sensor detects the position of
the ball. The change in the position is amplified
by the amp and is sent as a voltage change to
the power train controller.
q The input and output characteristics of the sensor are shown in the figure on the right.

D375A-6

10-223

Electrical system
Sensor

Speed sensor

10-2 3-1

1. Sensor
2. O-ring
3. Connector
4. Wire
10-2 3-1
Speed sensor, which is installed in the case of
the cooling fan motor, detects gear speed as
pulse signals from cylinder block spline inside
the motor and sends them as converted electric
signals to the controller.
Since the clearance between the sensor and
spline is controlled to the specified dimension,
adjustment at installation is not necessary.

Function
q

10-223-1

D375A-6
(04)

Electrical system
Sensor

Engine oil level sensor

1. Connector
2. Bracket

10-2 3-2

3. Float
4. Switch

Air cleaner clogging sensor

1. Spring
2. Switch
3. Hose

10-2 3-2

4. Sensor
5. O-ring
6. Connector

Hydraulic oil level sensor

1. Float
2. Sensor
3. Tube

D375A-6
(04)

4. Wire
5. Connector

10-223-2

DRAFT
Electrical system
Vehicle health monitoring system (VHMS)

Vehicle health monitoring system (VHMS)


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

If the "ORBCOMM terminal system" is installed


to the machine, it can transmit the data recorded
in the VHMS by satellite communication to the
administrator or the service department,
allowing for remote machine management.
For the use of the VHMS, see "30 Testing and
adjusting" of this manual.

VHMS controller

Note 1. VHMS is an abbreviation of Vehicle Health Monitoring System.

10-224

D375A-6

DRAFT
Electrical system
Vehicle health monitoring system (VHMS)

Input and output signals


CN1 [CN 1]
Pin No.

Signal name

CN2 [CN2 A, B]
Input/output

Pin No.

Signal name

Input/output

CN2-A1

NC

CN1-1

NC

CN1-2

Sensor power supply (24 V)

Output

CN2-A2

NC

CN1-3

Sensor power supply (12 V)

Output

CN2-A3

NC

CN1-4

Sensor power supply (5 V)

Output

CN2-A4

NC

CN1-5

Sensor power supply (5 V)

Output

CN2-A5

Exhaust temperature (Rear)

Input

CN2-A6

NC

Input

CN2-A7

Exhaust temperature (Front)

CN1-6
CN1-7

Power supply (Constant power


supply) (24 V)
Power supply (Constant power
supply) (24 V)

Input
Input

CN1-8

BR power supply (24 V)

Input

CN2-A8

NC

CN1-9

BR power supply (24 V)

Input

CN2-A9

CONNECTOR SEL0 (OPEN)

Input

CN1-10

NC

CN2-A10

Ambient temperature

Input

CN1-11

GND

CN2-A11

NC

CN1-12

GND

CN2-A12

Sensor GND

CN1-13

NC

CN2-A13

Sensor GND

CN1-14

NC

CN2-A14

NC

CN1-15

NC

CN2-A15

Transmission, main oil pressure

CN1-16

NC

CN2-A16

NC

CN1-17

Start signal

Input

CN2-A17

WAKE UP (Low)

Input

CN1-18

NC

CN2-A18

Blowby pressure

Input

CN1-19

GND

CN2-B1

NC

CN1-20

GND

CN2-B2

NC

CN2-B3

NC

CN2-B4

NC

CN2-B5

NC

CN2-B6

WAKE UP (Hi)

CN2-B7

NC

CN2-B8

NC

CN2-B9

GND

CN2-B10

NC

CN2-B11

NC

CN2-B12

CONNECTOR SEL1 (GND)

D375A-6

Input
-

Input

Input

10-225

DRAFT
Electrical system
Vehicle health monitoring system (VHMS)

CN3 [CN3 A, B]
Pin No.

CN4 [CN4 A, B]
Signal name

Input/output

Pin No.

CN4-A1

NC

Input

CN4-A2

NC

Signal name

Input/output

CN3-A1

NC

CN3-A2

CAB out D/L Sw

CN3-A3

NC

CN4-A3

NC

CN3-A4

NC

CN4-A4

CAN (1) H (KOM-NET/c)

CN3-A5

Model selection (See ORB connection)

Input

CN4-A5

CAN (0) shield (MMS)

CN3-A6

NC

CN4-A6

CAN (0) H (MMS)

CN3-A7

NC

CN4-A7

NC

CN3-A8

NC

CN4-A8

NC

CN3-A9

CONNECTOR SEL2 (GND)

Input

CN4-A9

GND

CN3-A10

NC

CN4-A10

RS232C RXD (PC Tool)

Input

CN3-A11

NC

CN4-A11

RS232C TXD (PC Tool)

Output

CN3-A12

NC

CN4-A12

CAN (1) L (KOM-NET/c)

Input/output

CN3-A13

NC

CN4-A13

CAN (1) SH (KOM-NET/c)

CN3-A14

NC

CN4-A14

CAN (0) L (MMS)

CN3-A15

NC

CN4-B1

NC

CN3-A16

NC

CN4-B2

NC

CN3-A17

NC

CN4-B3

GNG (Orbcomm)

CN3-A18

NC

CN4-B4

RS232C TX1 (Orbcomm)

CN3-B1

NC

CN4-B5

NC

CN4-B6

NC

CN3-B2

NC

CN4-B7

NC

CN3-B3

NC

CN4-B8

NC

CN3-B4

NC

CN4-B9

GND (Orbcomm)

CN3-B5

NC

CN4-B10

RS232C RX1 (Orbcomm)

CN3-B6

NC

CN3-B7

NC

Pin No.

CN3-B8

NC

CN5-1

LAN TX+

Output

CN3-B9

NC

CN5-2

LAN TX-

Output

CN3-B10

NC

CN5-3

LAN RX+

Input

CN3-B11

NC

CN5-4

LAN RT3

CN3-B12

CONNECTOR SEL3 (OPEN)

CN5-5

LAN RT4

CN5-6

LAN RX-

Input

CN5-7

LAN RT1

CN5-8

LAN RT2

CN5-9

NC

CN5-10

NC

CN5-11

PWR (LAN5 V)

CN5-12

GND (LAN)

10-226

Input

Input/output
Input/output

Input/output

Output

Input

CN5
Signal name

Input/output

Output
-

D375A-6

DRAFT
Electrical system
Vehicle health monitoring system (VHMS)

Sensors

Exhaust temperature sensor/amplifier

Engine oil temperature sensor


Specification
Type of sensor: Thermistor
Measurement range : 40 130 C
80 130 C
(Assured accuracy: 2 C)
Max. power consumption:0.5 mW
Pressure capacity: 4.9 MPa {50 kg/cm2}
Operating temperature: -30 C +140 C
Performance table

Specification
Rated voltage: 24V DC
Delectable temperature range: 100 1,000 C
300 800 C
(Assured accuracy: 10 C)
Output voltage characteristics
(Ambient temperature: 20 C)
Reference values

Tem-pe Resis-ta Tem-pe Resis-ta Tem-pe Resis-ta


ra-ture
nce
ra-ture
nce
ra-ture
nce
(C)
(k)
(C)
(k)
(C)
(k)
30

35.27

80

6.571

110

2.887

40

24.28

85

5.682

115

2.544

50

17.05

90

4.931

120

2.248

60

12.20

95

4.293

125

1.992

70

8.884

100

3.750

130

1.769

a. Heat sensing part of sensor


Outside diameter of mounting part: R1/4

Sensed tempera50
100
400
700
800
ture (C)
Output voltage
1.191 1.397 2.626 3.899 4.316
(V)

Operating temperature range: - 40 +110 C


Current consumption: Max. 30 mA
a. Heat sensing part of sensor
Outside diameter of mounting part: R1/8
b. Amplifier
c. Connector (power supply side)
d. Connector (sensor side)
Function
The exhaust temperature sensor/amplifier is a thermocouple-type temperature sensor, which is installed to the turbocharger inlet. It outputs the
exhaust temperature data to the VHMS controller.

Function
The engine oil temperature sensor is installed to the
engine oil filter. It inputs the change of the temperature as the change of the thermistor resistance to
the VHMS controller.

D375A-6

10-227

DRAFT
Electrical system
Vehicle health monitoring system (VHMS)

Ambient temperature sensor


Specification
Power consumption: Max. 0.5 mW
Pressure capacity: 0.98 MPa {10 kg/cm2}
Delectable temperature range (ambient):
- 30 + 120 C
Storage temperature range: - 50 + 140 C
Performance table
Detected
temperature (C)
Resistance
(k)

-20

-10

10

20

50

30.32 18.58 11.74 7.623 5.077 1.712

a. Heat sensing part of sensor


Outside diameter of mounting part: 16 1.5
Function
The ambient temperature sensor inputs the change
of the ambient temperature as the change of the
thermistor resistance to the VHMS controller.

10-228

D375A-6

DRAFT
Electrical system
Vehicle health monitoring system (VHMS)

Engine blowby pressure sensor

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

Specifications and function


Pressure range: 0 20 kPa
{0 2,040 mmH2O}
Allowable pressure: -20 100 kPa
{-2,040 10,200 mmH2O}
Source voltage: 5 0.25 V
Output characteristics: See graph.
q The blowby pressure sensor is a minute relative
pressure type sensor, which measures the difference between the pressure in the crankcase
and ambient pressure.
q The pressure in the crankcase is introduced to
the tip of the sensor and the ambient pressure is
introduced to the wiring harness side.

Transmission main oil pressure sensor


1. Sensor
2. Connector

D375A-6

10-229

DRAFT
Electrical system
ORBCOMM system

ORBCOMM system

Outline
q The ORBCOMM terminal system is a communication system to use the satellite communication
service of ORBCOMM Co., Ltd. (USA). If this
system is installed to the machine, the data recorded in the VHMS controller and various information obtained through the network in the
machine can be transmitted by the satellite communication.
q It is required to sign up for the ORBCOMM terminal system before using its functions.
For details, including the sign-up test, see "30
Testing and adjusting" of this manual.
q The ORBCOMM terminal system may or may
not be installed to the machine, depending on
the user's purchase specification.

10-230

D375A-6

DRAFT
Electrical system
ORBCOMM system

ORBCOMM terminal system

1. Communication antenna connection


2. DRC connector connection (40 poles)
Outline
q The ORBCOMM terminal obtains various kinds
of machine information from the network signals
and input signal in the machine and transmits
them via the wireless communication antenna. It
contains a CPU (Central Processing Unit) and
has wireless communication function.
q This terminal has a LED lamp unit and a 7-segment display lamp unit used for inspection and
troubleshooting.
Input/Output signal
q DRC conector

18

NC

19

NC

20

NC

21

NC

22

NC

23

NC

24

NC

25

NC

26

NC

NC

27

NC

NC

28

NC

NC

29

DOUT (GND)

COMM 232C RXD

30

NC

COMM 232C TXD

31

NC

NC

32

NC

NC

33

NC

NC

34

NC

NC

35

NC

10

NC

36

ACC Input

11

RS232C GND

37

DIS_SEL0 (GND)

12

NC

38

DIS_SEL0 (GND)

13

NC

39

Constant power supply (24 V)

14

NC

40

Constant power supply (24 V)

15

NC

16

NC

17

NC

D375A-6

10-231

DRAFT
Electrical system
ORBCOMM system

Antenna
Specification
Type: Helical whip antenna (1)
Impedance: 50
Input terminal: M-P type
Length: 165 20 mm
a. Communication antenna mounting part
Function
Transmits data collected and stored by the VHMS
controller to the computer center via communications satellites.

10-232

D375A-6

DRAFT

D375A-6
SEN05175-00

BULLDOZER
D375A-6
Shop Manual

Machine model
D375A-6

Serial number
60001 and up

20 Standard value table


Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

20-

2
Standard value table for engine - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

20-

3
Standard value table for machine- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

20-

D375A-6
(01)

20-1

DRAFT
Contents

Contents
20 Standard value table
Standard service value table ............................................................................................................................ 20Standard value table for engine .................................................................................................................... 20Standard value table for machine ................................................................................................................. 20-

20-2

3
3
4

D375A-6
(01)

Standard service value table


Standard value table for engine

Standard service value table

20-3

Standard value table for engine

20-3

Machine model

D375A-6

Engine
Item

Measurement conditions

Engine speed

High idle
Low idle
Rated speed

Boost pressure

At rated horsepower

Exhaust temperature
Exhaust gas color
Valve clearance
(Normal temperature)
EGR valve drive oil
pressure
(Oil temperature: 40
60 C)
Compression pressure
(SAE15W-40 or SAE30
oil)
Blow-by pressure
(SAE15W-40 or SAE30
oil)
Oil pressure
(Oil temperature: 90
110 C)
Oil temperature
Alternator belt tension
Air conditioner compressor belt tension

D375A-6
(06)

Whole speed range (Ambient temperature: 20 C)


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

SAA6D170E-5

kPa
{mmHg}

Standard value for


new machine
1,900 (0/-50)
750 50
1,800
Min. 155
{Min. 1,160}

Permissible
value
1,900 (0/-50)
750 50
1,800
Max. 141
{Max. 1,060}

Max. 700

Min. 730
Min. 3.5
Min. 2.0

MPa
{kg/cm2}
(rpm)

Max. 2.5
Max. 1.0
0.32
0.62
Min. 1.18
{Min. 12}
Min. 1.43
{Min. 14.6}
Min. 2.94
{Min. 30}
(210 250)

Max. 2.1
{Max. 21}

kPa
{mmH2O}

Max. 3.43
{Max. 350}

Min. 9.41
{Min. 960}

Min. 392.27
{Min. 4.0}

Max. 235.36
{Max. 2.4}

Min. 117.68
{Min. 1.2}

Max. 78.45
{Max. 0.8}

90 110

Min. 120

mm

(Auto-tension)

mm

(Auto-tension)

Unit
rpm

Bosch index
mm
MPa
{kg/cm2}

kPa
{kg/cm2}

20-3

DRAFT
Standard service value table
Standard value table for machine

Standard value table for machine


Machine model
Category

Item

Engine speed

Decelerator pedal
low speed

Measuring condition

q
q
q
q

Torque converter
stall speed

q
q
q

Torque converter
stall + Work equipment relief speed

q
q

Control lever/pedal stroke

PCCS Lever

Forward and
reverse

Engine stopped
Center of lever knob

q
q
q

Brake pedal

Engine stopped
Center of pedal
Engine low idle
Center of pedal

q
q

mm

mm
Full stroke
Until oil pressure becomes
zero

rpm

Neutral o Forward
Neutral o
Reverse
All stroke
(Neutral
Right/Left)
Until clutch is
fully disengaged

Blade control lever

Unit

Working mode: P-mode


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

Steering

Decelerator pedal

D375A-6

Engine low idle


Hydraulic oil temperature: 45 Neutral Raise
55 C
Center of lever knob
Neutral Float

Ripper control lever


q

20-4

Engine low idle


Neutral
Hydraulic oil temperature: 45 Raise/Lower
55 C
Neutral Tilt
Center of lever knob
forward/back

Permissible
value

900 50

900 50

1,530 50

1,450

1,500 50

1,400

30 5

Max. 8.0

30 5

30 5

40 5
40 5
(Play: Max.
(Play: Max. 3)
3)
95

95

45 15

45 15

75 5

75 5

54 5

54 5

60 10

60 10

85 10

85 10

53 10

53 10

78 10

78 10

81 10

81 10

mm

mm

Neutral
Left/Right tilt
q

Standard
value for new
machine

mm

D375A-6
(03)

Standard service value table


Standard value table for machine

Machine model
Cate
gory

Item

Left

Engine stopped
Center of lever knob

Right

PCCS lever

Control lever/pedal operating effort


Control lever/pedal operating effort

Steering

Brake pedal

q
q
q
q
q

Blade control
lever

q
q

Ripper control
lever

Min. speed
Fan

Permissible
value

Neutral o Forward

56.9 6.9
{5.8 0.7}

56.9 6.9
{5.8 0.7}

Neutral o
Reverse

56.9 6.9
{5.8 0.7}

56.9 6.9
{5.8 0.7}

12.8 3.9
{1.3 0.4}

12.8 3.9
{1.3 0.4}

16.7 4.9
{1.7 0.5}

16.7 4.9
{1.7 0.5}

Until clutch is
fully disengaged

13.7 3.9
{1.4 0.4}

13.7 3.9
{1.4 0.4}

At stroke end

19.6 4.9
{2 0.5}

19.6 4.9
{2 0.5}

Until clutch is
fully disengaged
At stroke end

Decelerator pedal

Max. speed
Circuit oil pressure

D375A-6
(06)

Standard
value for new
machine

Measuring condition
q

Forward and
reverse

D375A-6

q
q

Unit

N
{kg}

Engine stopped
Center of pedal

N
{kg}

49.0 9.8
{5.0 1.0}

49.0 9.8
{5.0 1.0}

Engine at low idle


Center of pedal

N
{kg}

460.6 49.0
{47.0 5.0}

460.6 49.0
{47.0 5.0}

39.2 5.9
{4.0 0.6}

39.2 5.9
{4.0 0.6}

82.3 9.8
{8.4 1.0}

82.3 9.8
{8.4 1.0}

Neutral
Left/Right tilt

28.4 4.9
{2.90.5}

28.4 4.9
{2.90.5}

Engine at low idle


Neutral
Hydraulic oil temperature: 45 Raise/Lower
55 C
Center of lever knob
Neutral Tilt
forward/back

21.6 4.9
{2.20.5}

21.6 4.9
{2.20.5}

20.6 4.9
{2.10.5}

20.6 4.9
{2.10.5}

350 100

1,210 25

Max. 1,110

15.7 2.5
{16025}

15.7 2.5
{16025}

Engine at low idle


Hydraulic oil temperature: 45 Neutral o Raise
55 C
Center of lever knob
Neutral o Float

Fan 100 % mode


Engine at low
Hydraulic oil temperature: Min. idle
40 C
Engine at high
idle
Engine at high
idle

N
{kg}

N
{kg}

rpm

MPa
{kg/cm2}

20-5

Standard service value table


Standard value table for machine

Machine model
Cate
gory

Item

Standard
value for new
machine

Permissible
value

Engine at low
idle

0.03 0.25
{0.3 2.5}

0.03 0.25
{0.3 2.5}

Engine at high
idle

0.69 1.05
{7.0 10.7}

0.69 1.05
{7.0 10.7}

Engine at low
idle

0.03 0.20
{0.3 2.0}

0.03 0.20
{0.3 2.0}

0.44 0.70
{4.5 7.0}

0.44 0.70
{4.5 7.0}

Engine at high
idle

1.29 1.54
{13.2 15.7}

1.29 1.54
{13.2 15.7}

Engine at low
idle

2.25 2.87
{23.0 29.3}

2.25 2.87
{23.0 29.3}

Engine at high
idle

2.55 2.87
{26.0 29.3}

2.55 2.87
{26.0 29.3}

Engine at low
idle

2.48 2.87
{25.3 29.3}

2.38 3.07
{24.3 31.3}

Engine at high
idle

2.68 2.87
{27.3 29.3}

2.58 3.07
{26.3 31.3}

Adjustment ID: 5535 Engine at low


Measure in (both
idle
steering clutch disenEngine at high
gage modes)
idle

2.25 2.84
{23.0 29.0}

2.06 3.13
{21.0 31.9}

2.55 2.87
{26.0 29.3}

2.35 3.16
{23.9 32.2}

2.25 2.84
{23.0 29.0}

2.06 3.13
{21.0 31.9}

Engine at high
idle

2.55 2.87
{26.0 29.3}

2.35 3.16
{23.9 32.2}

Engine at low
idle

2.06 2.35
{21.0 24.0}

1.86 2.55
{18.9 26.0}

Engine at high
idle

2.06 2.35
{21.0 24.0}

1.86 2.55
{18.9 26.0}

Measuring condition
q

Torque converter
inlet pressure

Power train oil temperature:


Within operating range

Torque converter
outlet pressure

Engine at high
idle
Engine at low
idle

Power train oil pressure

Torque converter
lockup clutch
pressure

Torque converter
stator clutch
pressure
q

Transmission
main relief pressure

Power train oil temperature:


Within operating range

Transmission F
clutch pressure

Transmission R
clutch pressure

Transmission 1st
clutch pressure

20-6

D375A-6

Engine at low
idle

Unit

MPa
{kg/cm2}

MPa
{kg/cm2}

D375A-6
(06)

DRAFT
Standard service value table
Standard value table for machine

Machine model
Category

Item

D375A-6

Measuring condition
q

Transmission 2nd
clutch pressure

Adjustment ID: 5535


Measure in (both
steering clutch disengage modes)

Unit

Power train oil pressure

Transmission lubricating oil pressure

2.25 2.84
2.06 3.13
{23.0 29.0} {21.0 31.9}

Engine high
idle

2.55 2.87
2.30 3.16
{26.0 29.3} {23.4 32.2}

Engine high
idle

2.55 2.87
2.30 3.16
{26.0 29.3} {23.4 32.2}

Power train oil temperature:


Within operating range

Engine high
idle

0.08 0.25
{0.8 2.5}

Power train oil temperature:


Within operating range

Engine low idle

2.25 2.84
2.2 3.04
{23.0 29.0} {22.4 31.0}

Engine high
idle

2.55 2.87
2.4 3.07
{26.0 29.3} {24.4 31.3}

Engine low idle

2.25 2.84
2.2 3.04
{23.0 29.0} {22.4 31.0}

Engine high
idle

2.55 2.87
2.4 3.07
{26.0 29.3} {24.4 31.3}

Steering left brake


pressure

Engine low idle


Steering right clutch
pressure

Steering right brake


pressure
Power train oil temperature:
Within operating range

Flat ground
Engine coolant temperature: Within operating
range
Power train oil temperature: Within operating
range
Engine high idle
Run up distance: 10 - 30
m
Measurement distance:
20 m

Power train performance

q
q

D375A-6
(03)

MPa
{kg/cm2}

0.08 0.25
{0.8 2.5}

2.25 2.84
2.2 3.04
{23.0 29.0} {22.4 31.0}

Engine high
idle

2.55 2.87
2.4 3.07
{26.0 29.3} {24.4 31.3}

Engine low idle

2.25 2.84
2.2 3.04
{23.0 29.0} {22.4 31.0}

Engine high
idle

2.55 2.87
2.4 3.07
{26.0 29.3} {24.4 31.3}

Engine high
idle

Automatic gear shift mode

Travel speed

MPa
2.25 2.84
2.06 3.13
{kg/cm2} {23.0 29.0} {21.0 31.9}

Steering left clutch


pressure

Pin puller operating


pressure

Permissible
value

Engine low idle

Engine low idle


Transmission 3rd
clutch pressure

Standard
value for new
machine

MPa
{kg/cm2}

2.55 0.10
{26.0 1.0}

Min. 2.2
{Min. 22}

F1

20.6 1.0
{3.5 0.2}

20.6 1.0
{3.5 0.2}

F2

10.6 0.6
{6.8 0.3}

10.6 0.6
{6.8 0.3}

F3L

9.0 0.4
{8.0 0.4}

9.0 0.4
{8.0 0.4}

F3

6.1 0.3
{11.8 0.6}

6.1 0.3
{11.8 0.6}

R1

15.7 0.8
{4.6 0.2}

15.7 0.8
{4.6 0.2}

R2

8.1 0.4
{8.9 0.4}

8.1 0.4
{8.9 0.4}

R3L

7.4 0.3
{9.7 0.5}

7.4 0.3
{9.7 0.5}

R3

4.9 0.3
{15.8 0.7}

4.9 0.3
{15.8 0.7}

sec
{km/h}

20-7

DRAFT
Standard service value table
Standard value table for machine

Machine model

Item
q

Power train performance

Travel speed

q
q
q

Unload pressure

Work equipment oil pressure

Blade tilt relief pressure

Ripper tilt relief


pressure

LS pressure
(Load sensing pressure)

20-8

Permissible
value

Flat ground
Engine coolant temperature: Within operating
range
Power train oil temperature: Within operating
range
Engine high idle
Run up distance: 10 - 30
m
Measurement distance:
20 m

F1

20.6 1.0
{3.5 0.2}

20.6 1.0
{3.5 0.2}

F2

10.6 0.6
{6.8 0.3}

10.6 0.6
{6.8 0.3}

6.1 0.3
{11.8 0.6}

6.1 0.3
{11.8 0.6}

15.7 0.7
{4.6 0.3}

15.7 0.7
{4.6 0.3}

R2

8.2 0.4
{8.7 0.4}

8.2 0.4
{8.7 0.4}

R3

4.9 0.3
{14.7 0.7}

4.9 0.3
{14.7 0.7}

Unit

F3
R1

q
q
q
q

sec
{km/h}

Hydraulic oil temperature: 45


Engine low idle
55 C
Cylinder stroke end
Engine high
idle

2.45 (+1.37/0)
{25 (+14/0)}

2.45
(+1.37/0)
{25 (+14/0)}
26.4 29.4
{270 300}

Engine low idle

26.4 28.4
{270 290}

Engine high
idle

27.4 29.4
27.4 29.4
{280 300} {280 300}

Engine low idle

Ripper lift relief


pressure

Control circuit oil


pressure
PPC valve output
pressure

Standard
value for new
machine

Measuring condition

Manual gear shift mode

Category

D375A-6

MPa
{kg/cm2}

26.4 28.4
{270 290}

26.4 29.4
{270 300}

Engine high
idle

27.4 29.4
27.4 29.4
{280 300} {280 300}

Engine low idle

26.4 28.4
{270 290}

Engine high
idle

27.4 29.4
27.4 29.4
{280 300} {280 300}

Engine low idle

25.48 1.27
{260 13}

25.48 1.27
{260 13}

25.48 1.27
{260 13}
3.43 4.12
{35 42}
3.43 4.12
{35 42}

25.48 1.27
{260 13}
3.43 4.12
{35 42}
Min. 3.33
{Min. 34}

Engine high
idle
Hydraulic oil temperature: 45 55 C
Engine high idle
Circuit oil pressure: Lever in neutral
Output pressure: Lever at stroke end

MPa
{kg/cm2}

26.4 29.4
{270 300}

D375A-6
(03)

DRAFT
Standard service value table
Standard value table for machine

Machine model
Category

Item

D375A-6
Standard
value for new
machine

Permissible
value

7 13

20

3.7 4.7

Engine low idle

1.3 1.7

1.3 1.8

Engine high
idle

1.3 1.7

1.3 1.8

24

2.5 3.5

24

2.5 3.5

46

2.5 3.5

46

2.5 3.5

24

2.5 3.5

24

2.5 3.5

Measuring condition

Unit

Raise

Engine low idle


Engine high
idle

Blade lift
q
q

L.H. tilt

Hydraulic oil temperature: 45 55 C


Apply no load to blade.
Between ground level
and rising end of blade

Lower

sec

Engine low idle


Engine high
idle
sec

L.H. tilt
q

Single tilt specification

Hydraulic oil temperature: 45 55 C


Apply no load to blade.
Between left tilt end and
right tilt end

L.H. tilt

Engine low idle


Engine high
idle

Engine high
idle

Engine low idle


Engine high
idle
sec

q
q
q

D375A-6
(03)

Engine high
idle

sec

Blade
dual tilt

Engine low idle

Engine low idle


R.H. tilt

Dual tilt specification

Hydraulic oil temperature: 45 55 C


Apply no load to blade.
Between left tilt end and
right tilt end

Hydraulic oil temperature: 45 55 C


Apply no load to blade.
Between left tilt end and
right tilt end

R.H. tilt

Work equipment speed

Work equipment

R.H. tilt

Blade tilt

Engine low idle


Engine high
idle

20-9

DRAFT
Standard service value table
Standard value table for machine

Machine model
Category

Measuring condition

Dump

Item

D375A-6

Blade pitch

q
q

Tilt in

Work equipment

Hydraulic oil temperature: 45 55 C


Apply no load to ripper.
Between ground level
and rising end of ripper

q
q
q

q
q

Time lag

Blade

Hydraulic oil temperature: 45 55 C


Apply no load to blade.
Between forward tilt end
and backward tilt end

Engine high
idle

Engine high
idle

Engine low idle


Engine high
idle

sec

2.5 3.5

35

2.5 3.5

*G

46

*M

46

*G

23

7
5

*M 2.5 3.5

Engine low idle

1.5 2.5

1.5 2.5

Engine high
idle

1.5 2.5

1.5 2.5

Engine low idle

10 16

20

Engine high
idle

4.5 5.5

6 10

15

2.8 3.8

Max. 8

12

Max. 1.8

2.0

Engine low idle


Engine high
idle

Hydraulic oil temperature: 45


55 C
Engine low idle
Lever full stroke
Start lowering operation at blade
max. raising position and mea- Engine high
sure time from when blade idle
reaches ground until idler rises.

sec
Hydraulic oil temperature: 45
55 C
Engine low idle
q Lever full stroke
q Start lowering operation at ripper
Ripper
max. raising position and measure time from when ripper Engine high
reaches ground until sprocket idle
rises.
* G: Variable giant ripper specification, M: Variable multi-shank ripper specification

20-10

46

Engine low idle

sec
Tilt back

Ripper tilt

Permissible
value

sec

RAISE
Ripper lift

Standard
value for new
machine

Engine low idle

LOWER

Work equipment speed

Hydraulic oil temperature: 45 55 C


Apply no load to blade.
Between dump end and
back end

Back

Unit

*G Max. 1.0 *G

1.5

*M Max. 1.5 *M

D375A-6
(03)

Standard service value table


Standard value table for machine

Machine model
Cate
gory

Item

Measuring condition

Hydraulic
drift of lifted
blade
q
q
q

Hydraulic drift

Work equipment

q
q

q
q

q
q

D375A-6
(06)

Permissible
value

mm

Max. 65 mm

130 mm

mm

Max. 50 mm

100 mm

mm

Max. 50 mm

80 mm

mm

Max. 25 mm

50 mm

Hydraulic oil temperature: 45 55 C


Engine stopped
Measuring reduction of track shoe bottom height
"h" (for 5 minutes).

Hydraulic
drift of lifted
ripper
q

Standard
value for new
machine

Hydraulic oil temperature: 45 55 C


Engine stopped
Measure reduction of idler center height "h" (for
5 minutes).

Hydraulic
drift of
machine
tilted by
blade
q

Unit

Hydraulic oil temperature: 45 55 C


Engine stopped
Measuring reduction of blade bottom height "h"
(for 5 minutes).

Hydraulic
drift of lifted
blade
q

D375A-6

Hydraulic oil temperature: 45 55 C


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

20-11

DRAFT
Standard service value table
Standard value table for machine

Machine model

20-12

Hydraulic drift

Item

Measurement condition

Hydraulic drift
of machine
lifted by ripper
q
q
q

Cylinder internal leakage

Work equipment

Category

Blade tilt cylinder


Ripper lift cylinder
Ripper tilt cylinder

q
q
q

Hydraulic oil temperature: 45 55 C


Engine stopped
Measure reduction of sprocket center height
"h" (for 5 minutes).
Engine running at low idle
Hydraulic oil temperature: 45 55 C
Relieve cylinder and measure leakage for 1
minute.

D375A-6
Unit

Standard
value for new
machine

Permissible
vable

mm

Max. 30 mm
per 5 minutes

60 mm per 5
minutes

Max. 3.0

12

Max. 3.6

12

Max. 3.2

12

cc/min

D375A-6
(01)

DRAFT

D375A-6
SEN05176-00

BULLDOZER
D375A-6
Shop Manual

Machine model
D375A-6

Serial number
60001 and up

30 Testing and adjusting


Contents - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 2
Tools for testing, adjusting, and troubleshooting - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 4
Testing intake air pressure (boost pressure) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 8
Testing exhaust gas color - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 12
Adjusting valve clearance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 14
Measuring compression pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 16
Testing blow-by pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 19
Testing engine oil pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 21
Handling of fuel system devices- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 24
Releasing residual pressure from fuel system - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 25
Bleeding air from fuel circuit - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 31
Testing fuel pressure - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 30 26

D375A-6
(01)

30-1

Contents

Contents
30 Testing and adjusting
Tools for testing, adjusting and troubleshooting .....................................................................
Diagnosis equipment list ......................................................................................................
Engine and cooling system .....................................................................................................
Testing engine speed...........................................................................................................
Testing intake air pressure (boost pressure) .......................................................................
Testing exhaust temperature ...............................................................................................
Testing exhaust gas color ....................................................................................................
Adjusting valve clearance ....................................................................................................
Measuring compression pressure........................................................................................
Testing blow-by pressure.....................................................................................................
Testing engine oil pressure..................................................................................................
Testing EGR valve drive oil pressure...................................................................................
Handling of fuel system devices ..........................................................................................
Releasing residual pressure from fuel system .....................................................................
Testing fuel pressure ...........................................................................................................
Handling of reduced cylinder mode operation .....................................................................
Handling of no injection cranking operation .........................................................................
Testing leakage from pressure limiter and return rate from injector ....................................
Bleeding air from fuel circuit.................................................................................................
Testing fuel circuit for leakage .............................................................................................
Replacing and adjusting alternator and air conditioner compressor belt .............................
Measuring fan speed ...........................................................................................................
Testing fan circuit oil pressure .............................................................................................
Bleeding air from fan pump..................................................................................................
Adjusting fuel control dial and decelerator pedal .................................................................
Power train..............................................................................................................................
Testing power train oil pressure...........................................................................................
Adjusting transmission output speed sensor .......................................................................
Simple test procedure for brake performance......................................................................
Adjusting brake pedal and parking brake lever....................................................................
Adjusting position of pccs lever console ..............................................................................
Emergency escape method when there is failure in power train .........................................
Undercarriage and frame ........................................................................................................
Inspecting wear of sprocket .................................................................................................
Testing and adjusting track shoe tension.............................................................................
Hydraulic system.....................................................................................................................
Measuring and adjusting work equipment oil pressure........................................................
Testing control circuit main pressure ...................................................................................
Testing PPC valve output pressure .....................................................................................
Adjusting play of PPC valve.................................................................................................
Testing output pressure of ripper pin-puller solenoid valve .................................................
Checking location of cause of hydraulic drift of blade and ripper.........................................
Testing leakage inside work equipment cylinder .................................................................
Releasing remaining pressure in work equipment cylinders................................................
Bleeding air from work equipment cylinders ........................................................................
Adjusting ripper lever position..............................................................................................
Work equipment......................................................................................................................
Adjusting work equipment lock lever....................................................................................
Adjusting blade ....................................................................................................................
Cab and its attachments .........................................................................................................

30-2

30-2
3030303030303030303030303030303030303030303030303030303030303030303030303030303030303030303030303030-

4
4
6
6
8
10
12
14
16
19
21
22
24
25
26
27
27
28
31
33
34
35
36
37
38
40
40
52
53
54
57
58
60
60
61
62
62
65
66
68
69
70
71
72
72
73
74
74
75
77

D375A-6
(07)

Contents

Testing and adjusting operator's cab ...................................................................................


Testing and adjusting operator's seat isolator .....................................................................
Electrical system .....................................................................................................................
Special functions of machine monitor (EMMS)....................................................................
Handling of voltage circuit of engine controller ....................................................................
Adjustment method when controller has been replaced......................................................
Preparation work for troubleshooting of electrical system ...................................................
Inspection procedure of diode .............................................................................................
Handling of optional devices................................................................................................
Request for opening ORBCOMM terminal ..........................................................................
Initialization procedures for VHMS controller.......................................................................
Using method of KOMTRAX functions of ORBCOMM terminal ..........................................
Precautions for replacing VHMS controller..........................................................................
Pm Clinic service ....................................................................................................................
Pm Clinic service .................................................................................................................

D375A-6
(07)

30- 77
30- 81-1
30- 82
30- 82
30- 139
30- 140
30- 144
30- 148
30- 149
30- 150
30- 152
30- 172
30- 175
30- 181
30- 181

30-3

Tools for testing, adjusting and troubleshooting


Diagnosis equipment list

Tools for testing, adjusting and troubleshooting

30-4

Diagnosis equipment list

30-4

Testing/Adjusting item

Symbol

Measuring intake air


pressure (boost pressure)
Measuring exhaust gas
temperature
Checking exhaust gas
color

Remarks

-101 200 kPa {-760 1,500 mmHg}

B
-

799-101-1502
799-201-1150
799-201-9001
Commerciallyavailable
Commerciallyavailable
795-502-1590
795-611-1220
6261-71-6150
795-799-5410
795-799-5420
799- 201-1504

Digital thermometer
Adapter connector
Handy smoke checker

1
1
1

-99.9 1,299C
For Pm clinic specification

Smoke meter

Clearance gauge

Compression gauge
Adapter
Gasket
Adapter
Remover
Blow-by checker

1
1
1
1
1
1

1
2
D

E 2
3

Testing blow-by pressure

Q'ty

799-201-2202 Boost gauge kit

1
Testing compression
pressure

Part Name

Adjustment of valve
clearance

Part No.

799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester

799-401-2320
799-101-5230
6215-81-9720
795T-690-1110
01435-00835
07000-E2012

1
1
1
1
2
3

1
Testing engine oil pressure

G 2
3

Testing drive pressure of


EGR valve

Gauge
Nipple
O-ring
Block
Bolt
O-ring

H 2
3
1
2
3

Testing fuel return rate


and leakage

4
5
6

Testing power train oil


pressure

1
2

Emergency retrieval
method when power train L
has trouble

2
Measuring and adjusting
1
work equipment oil presM
sure, Testing control cir2
cuit main pressure
Testing PPC valve output pressure

30-4

Intake side: 0.32 mm, Exhaust side:


0.62 mm
0 7 MPa {0 70 kg/cm2}

Pressure gauge: 2.5, 6, 40, 60 MPa


{25, 60, 400, 600 kg/cm2}
Pressure gauge: 60 MPa {600
kg/cm2}
Pressure gauge: 1.0 MPa {10 kg/cm2}

799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester

799-401-2320
799-101-5160
795-471-1450
07005-00812
6167-11-6640
6206-71-1770
Commerciallyavailable
Commerciallyavailable
Commerciallyavailable
Commerciallyavailable
799-101-5002
790-261-1204
799-401-2320
19M-06-32820
7824-66-6430
195-06-71220
790-190-1601
799-101-5002
790-261-1204
799-101-5220
07002-11023

Gauge
Nipple
Adapter
Gasket
Spacer
Joint

1
1
1
1
1
1

*As common as G2
R 1/8
M8 1.25

Hose

f 5 mm (Inside diameter) x 2 3 m

Hose

f 16 mm (Inside diameter) x 2 3 m

Measuring cylinder

Stopwatch

Hydraulic tester
Digital hydraulic tester
Gauge
Switch assembly
Resistor
Wiring harness
Pump assembly
Hydraulic tester
Digital hydraulic tester
Nipple
O-ring

1
1
1
1
1
1
1
1
1
2
2

1
Testing fuel pressure

Bosch index: 0 to 9

*As common as G1

799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester

N 1

Inside diameter: 10 mm
Joint diameter: 10 mm

*As common as G1
*As common as G2

*As common as G1
M10 1.25

*As common as G1

D375A-6
(06)

Tools for testing, adjusting and troubleshooting


Diagnosis equipment list

Testing/Adjusting item
Testing ripper pin puller
solenoid valve output
pressure

Symbol

Part Name

Q'ty

799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester

799-401-3200 Adapter
CommerciallyMeasuring cylinder
available

799-101-5002 Hydraulic tester

790-261-1204 Digital hydraulic tester

Testing for leakage inside


work equipment cylinder

Part No.

*As common as G1

Testing operating effort


and depressing force
Testing stroke and
hydraulic drift
Testing work equipment
speed
Testing voltage and resistance
Initialization of VHMS
controller

2
3
4
T
U
V

Diagnosis sensor and


harness

D375A-6
(06)

*As common as G1
790-301-1330
07372-21055
07000-13035
79A-264-0021
79A-264-0091
Commerciallyavailable
Commerciallyavailable
Commerciallyavailable

q Flange
Bolt
O-ring
Push-pull scale
Push-pull scale

1
4
1
1
1

Ruler

Stopwatch

Multimeter

799-608-3211 Discket

799-608-3220 Wiring harness

Size 03

1
Testing fan circuit oil
pressure

Remarks

Commerciallyavailable
799-601-7400
799-601-7500
799-601-9000
799-601-9300
799-601-7360
799-601-3450
799-601-4100
795-799-5530
795-799-5540
799-601-4130
799-601-4150
799-601-4211
799-601-4220
799-601-4240
799-601-4250
799-601-4260
799-601-9020
799-601-9040
799-601-9420
799-601-9430
799-601-9030

Lap top type personal


computer
T-adapter assembly
T-adapter assembly
T-adapter assembly
T-adapter assembly
Adapter
Adapter
T-adapter assembly
q T-adapter
q T-adapter
q T-adapter
q T-adapter
q T-adapter
q T-adapter
q Socket
q Socket
q T-adapter
q T-adapter
q T-adapter
q T-adapter
q T-adapter
T-adapter

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

Size: 10

0 294 N {0 30 kg}
0 490 N {0 50 kg}

OS: Windoes98/2000/Me/XP/VISTA
[With RS232C terminal]
AMP040 Connector
AMP040 Connector
DT, HD30 connector
DRC26-24, 40-pin
Relay (5 pins)
VHMS download harness
Connected with engine
Engine coolant, oil, fuel temperature
Boost air temperature sensor
Ne sensor
Oil pressure sensor
Controller (50 poles)
Controller (60 poles)
Ambient pressure sensor
Boost pressure sensor
Controller (4 poles)
EGR EGR valve, injector
EGR valve potentiometer sensor
Common rail pressure sensor
Supply pump PCV
G sensor

30-5

DRAFT
Engine and cooling system
Testing engine speed

Engine and cooling system


Testing engine speed
k

Stop the machine on level ground, lower the


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

2. Measuring low idle speed


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

30-6

3. Measuring high idle speed


1) Start the engine and set the fuel control dial
in the high idle (MAX) position.
2) Set the PCCS lever, blade control lever, and
ripper control lever in neutral and measure
the engine speed.
a The parking brake lever and work equipment lock lever may be kept in the LOCK
position.
4. Measuring decelerator pedal speed
1) Start the engine and set the fuel control dial
in the high idle (MAX) position.
2) Set the PCCS lever, blade control lever, and
ripper control lever in neutral, press the
decelerator pedal to the stroke end, and
measure the engine speed.
a The parking brake lever and work equipment lock lever may be kept in the LOCK
position.
5. Measuring torque converter stall speed
1) Start the engine and set the fuel control dial
in the low idle (MIN) position.
2) Operate the shiftup (UP) switch of the PCCS
lever and set the preset mode display section
to [F3-R3].
a The preset mode display section (at the
right bottom of the screen) can be set to
[F3-R3] only while the Adjustment function is selected.
3) While pressing the brake pedal securely, set
the parking brake lever in the free position
and set the direction of PCCS lever in the
forward position.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
4) Press the decelerator pedal and set the fuel
control dial in the high idle (MAX) position.
5) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idle.
k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the
work is finished.
6) Right after the power train oil temperature
gauge (T/C TEMPERATURE) indicates 118
C, return the PCCS lever to the neutral
position.

D375A-6
(03)

DRAFT
Engine and cooling system
Testing engine speed

a The top of the green range of the power


train oil temperature gauge indicates
about 118 120 C.
7) Repeat above steps 3) 6) 3 times.
8) Perform steps 3) - 5) again and measure the
engine speed when the power train oil
temperature gauge (T/C TEMPERATURE)
indicates 118 C.
a Immediately after finishing measuring, return the PCCS lever to the neutral position and lower the power train oil
temperature with the engine at high idle.
6. Measuring torque converter stall speed
(Inspection on Pm clinic screen)
1) Start the engine and set the fuel control dial
in the low idle (MIN) position.
2) Switch the machine monitor to the "Pm clinic"
function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

3) Operate the shiftup (UP) switch of the PCCS


lever and set the preset mode display section
to [F2-R2].
4) While pressing the brake pedal securely, set
the parking brake lever in the free position
and set the direction of PCCS lever in the
forward position.
5) Shift to 3rd gear by operating the shift-up
(UP) switch of PCCS lever.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
6) Repeat the measuring process in a similar
way by following Step 4) and later of "5.
Measuring torque converter stall speed".
7. Measuring torque converter stall + work equipment relief speed (Full stall speed)

1) Start the engine and set the fuel control dial


in the low idle (MIN) position.

D375A-6
(03)

2) Operate the shiftup (UP) switch of the PCCS


lever and set the preset mode display section
to [F3-R3].
a The preset mode display section (at the
right bottom of the screen) can be set to
[F3-R3] only while the Adjustment function is selected.
3) Set the work equipment lock lever in the free
position and operate the ripper control lever
to set the ripper lift cylinder to the raise stroke
end.
4) While pressing the brake pedal securely, set
the parking brake lever in the free position
and set the direction of PCCS lever in the
forward position.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
5) Press the decelerator pedal and set the fuel
control dial in the high idle (MAX) position.
6) Return the decelerator pedal slowly to stall
the torque converter with the engine at high
idle.
k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the
work is finished.
7) Right after the power train oil temperature
gauge (T/C TEMPERATURE) indicates 118
C, return the PCCS lever to the neutral
position.
a The top of the green range of the power
train oil temperature gauge indicates
about 118 120 C.
8) Repeat above steps 4) 7) 3 times.
9) Perform steps 4) - 6) again, operate the
ripper control lever to relieve the ripper raise
system, and measure the engine speed
when the power train oil temperature gauge
(T/C TEMPERATURE) indicates 118 C.
a Immediately after finishing measuring, return the PCCS lever to the neutral position and lower the power train oil
temperature with the engine at high idle.
8. Measuring torque converter stall + Work
equipment relief speed (Full stall speed)
(Inspection on Pm clinic screen)
1) Start the engine and set the fuel control dial
in the low idle (MIN) position.
2) Switch the machine monitor to the "Pm clinic"
function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

30-7

DRAFT
Engine and cooling system
Testing engine speed

3) Operate the shift up (UP) switch of the PCCS


lever and set the preset mode display section
to [F2-R2].
4) While pressing the brake pedal securely, set
the parking brake lever in the free position
and set the direction of PCCS lever in the
forward position.
5) Shift to 3rd gear by operating the shift-up
(UP) switch of PCCS lever.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
6) Repeat the measuring process in a similar
way by following Step 5) and later of "7.
Measuring torque converter stall + Work
equipment relief speed (Full stall speed)".

30-8
30-7-1

D375A-6
(03)

DRAFT
Engine and cooling system
Testing engine speed

D375A-6
(03)

30-7-2

DRAFT
Engine and cooling system
Testing intake air pressure (boost pressure)

Testing intake air pressure (boost


pressure)
a Testing instruments of intake air pressure (boost
pressure)
Symbol
A

Part No.
799-201-2202

Part name
Boost gauge kit

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
k When installing and removing the testing instrument, take care not to touch a hot part of
the engine.
a A nipple (quick coupler) is installed to the intake
air pressure (boost pressure) pickup port of the
Pm clinic specification machine.
a Measure the intake air pressure (boost pressure) under the following condition.
q Coolant temperature:
Within operating range
q Power train oil temperature:
Within operating range
q Hydraulic oil temperature: 45 55C
q Working mode: P-mode
q Gear shift mode: Manual
a Normally, the intake air pressure (boost pressure) should be tested while the engine is running at the rated output. In the field, however, an
approximate value can be obtained by stalling
the torque converter.

2) Test the boost pressure when the torque


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

3) Install nipple [1] of boost gauge kit A and


connect gauge [2].

1. Testing using machine monitor (Pm clinic)


1) Turn the starting switch to the ON position
and switch the machine monitor to the "Pm
clinic" function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a The VHMS specification machine is
shown as an example in the figure.

4) Run the engine at middle or higher speed


and bleed oil from the hose.

30-10
30-8

D375A-6
(03)

DRAFT
Engine and cooling system
Testing intake air pressure (boost pressure)

a Install the connecting parts of the gauge


and hose about a half and open the
self-seal on the hose side repeatedly, and
the oil will be drained.
a If Pm kit (A) is available, you use the
air-bleeding coupling (790-261-1130) in
that kit.
a If oil is left in the hose, the gauge does not
work. Accordingly, be sure to drain the oil.
5) Switch the machine monitor to the "Adjustment" function display of the service mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

6) Test the intake air pressure (boost pressure)


while the engine is running at high idle and
the torque converter is stalling.
a For the torque converter stall procedure,
see "5. Measuring torque converter stall
speed" of "Testing engine speed".
7) After finishing measuring, remove all test
tools in order to return the machine status as
it was.
q Remove the gasket sealant remaining on
the threads of the removed plug with a
wire brush and apply new adhesive or
gasket sealant to the plug before installing.
2 Plug: LT-2 or LG-5
3 Plug: 9.8 19.6 Nm {1.0 2.0 kgm}

D375A-6
(03)

30-9
30-11

DRAFT
Engine and cooling system
Testing exhaust temperature

Testing exhaust temperature


a Checking tools for exhaust gas temperature
Symbol
B

Part No.
799-101-1502

Part name
Digital thermometer

a Checking tools for exhaust gas temperature (for


Pm clinic specification machine)
Because each Pm clinic specification machine
has an exhaust gas temperature sensor,
prepare an adapter for the electrical connection
between the exhaust gas temperature sensor
and the digital temperature gauge.
Symbol
B

Part No.
799-101-1502
799-201-1150

Part name
Digital thermometer
Adapter connector

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
k Remove and install the testing tools after the
exhaust manifold temperature has lowered.
a Test the exhaust temperature under the following conditions.
q Engine coolant temperature: Within operating range
q Power train oil temperature:
Within operating range
q Hydraulic oil temperature: 45 55 C
q Working mode: P-mode
q Gear shift mode: Manual
1. Measuring with the digital temperature
gauge
1) Open the engine right side cover, and
remove the heat insulation cover.
2) Remove the exhaust
inspection plug.

gas

temperature

3) Install sensors [1] of digital temperature


gauge B and connect them to meter [2].
a Clamp the wiring harness of the digital
thermometer not to come into contact
with any hot parts during measuring.

30-12
30-10

4) Procedure for measuring at maximum


temperature while troubleshooting
Check the maximum exhaust gas temperature during actual operations.
a Use the digital temperature gauge in the
PEAK mode.
a The exhaust gas temperature largely depends on the ambient air temperature (intake air temperature of engine).
Accordingly, if any abnormal value is obtained, correct it using the following calculation.
q Corrected value [C] = Measured
value + 2 x (20 - Ambient temperature)
2. Periodic measurement procedure using the
preventive maintenance service (Pm clinic)
a If the torque converter alone has stalled, the
torque converter oil will overheat before the
exhaust gas temperature stabilizes. Therefore, check the exhaust gas temperature according to the following procedure.
1) Turn the starting switch to the ON position
and switch the machine monitor to the
"Adjustment" function display of the service
mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)"
section.

D375A-6
(03)

DRAFT
Engine and cooling system
Testing exhaust temperature
k

2) Run the engine to warm it up.


a The standard warm-up operation is as follows.
q Low idle: 3 minutes
q Run at a medium speed: 1 minute
q High idle: 1 minute
3) Set the fuel control dial to the low idle (MIN)
position.
4) Operate the shiftup (UP) switch of the PCCS
lever and set the preset mode display section
to [F3-R3].
a The preset mode display section (at the
right bottom of the screen) can be set to
[F3-R3] only while the Adjustment function is selected.
5) Set the work equipment lock lever in the free
position and operate the ripper control lever
to set the ripper lift cylinder to the raise stroke
end.
6) While pressing the brake pedal securely, set
the parking brake lever in the free position
and set the direction of PCCS lever in the
forward position.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
7) Press the decelerator pedal and set the fuel
control dial in the high idle (MAX) position.
8) Slowly release the decelerator pedal and
stall the torque converter at engine high idle
speed. Relieve the ripper raise system, and
measure the maximum exhaust gas temperature when the power train oil temperature
(T/C TEMPERATURE) shows 118 C.
k Keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the
work is finished.
9) Depress the decelerator pedal again.
10)Repeat Steps 8) and 9) several times and
record the highest exhaust gas temperature.

D375A-6
(03)

When the power train oil temperature


(T/C TEMPERATURE) reaches 118 C,
return the PCCS lever to the neutral
position immediately and lower the
power train oil temperature while the
engine is running at high idle speed.

11)After finishing measuring, remove all test


tools in order to return the machine status as
it was.
3. Testing for VHMS specifications
1) Turn the starting switch to the ON position
and switch the machine monitor to the "Pm
clinic" function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

2) Run the engine to warm it up.


a The standard warm-up operation is as follows.
q Low idle: 3 minutes
q Run at a medium speed: 1 minute
q High idle: 1 minute

30-11
30-13

DRAFT
Engine and cooling system
Testing exhaust temperature

3) Set the fuel control dial to the low idle (MIN)


position.
4) Operate the shiftup (UP) switch of the PCCS
lever and set the preset mode display section
to [F2-R2].
5) While pressing the brake pedal securely, set
the parking brake lever in the free position
and set the direction of PCCS lever in the
forward position.
6) Shift to 3rd gear by operating the shift-up
(UP) switch of the PCCS lever.
a Before going to the next step, check that
[F3] is displayed in the gear speed display
section (at the right bottom of the screen).
a Keep the steering unit in neutral.
7) Repeat the measuring process in the similar
way by following Step 5) and later of "2. Periodic measurement procedure using the
preventive maintenance service (Pm clinic)".

30-14
30-11-1

D375A-6
(03)

DRAFT
Engine and cooling system
Testing exhaust temperature

D375A-6
(03)

30-11-2
30-15

DRAFT
Engine and cooling system
Testing exhaust gas color

Testing exhaust gas color


a Checking tools for exhaust gas color
Symbol
1

Part No.
799-201-9001
Commercially
available

Part name
Handy smoke checker

2. Checking with smoke meter C2


1) Insert probe [1] of the smoke meter C2 into
the outlet of the exhaust pipe and fix it to the
exhaust pipe using a clip.

Smoke meter

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
k Be careful not to touch any hot part when removing or installing the checking tools.
a If an air source and an electric power source are
not available in the field, use a handy smoke
checker C1. When recording official data, use a
smoke meter C2.
a Check the exhaust gas color under the following
condition.
q Engine coolant temperature: Within operating range
q Working mode: P-mode
q Gear shift mode: Manual
1. Checking with a handy smoke checker C1
1) Stick a sheet of filter paper to smoke checker
C1.
2) Insert the exhaust gas intake pipe into the
exhaust pipe.
3) Start the engine.
4) Accelerate the engine suddenly or run it at
high idle and operate the handle of smoke
checker C1 so that the filter paper will absorb
the exhaust gas.

2) Connect the probe hose, receptacle of the


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

5) Remove the filter paper and compare it with


the attached scale.
6) After finishing checking, remove all test tools.

30-12

D375A-6
(03)

DRAFT
Engine and cooling system
Testing exhaust gas color

6) Start the engine.


7) Accelerate the engine suddenly or run at high
idle, and depress the accelerator switch of
smoke meter C2 at the same time to collect
the exhaust gas color on the filter.
8) Place the contaminated filter paper on the
clean filter paper (at least 10 sheets) in the
filter paper holder and read the indicated
value.
9) After testing, remove measuring tools and
reset the machine to its original status.

D375A-6
(01)

30-13

DRAFT
Engine and cooling system
Adjusting valve clearance

Adjusting valve clearance


a Adjusting tool for valve clearance

Symbol

Part No.

Commercially
available

Part name
Feeler gauge

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.

1. Remove the engine hood.


2. Remove cylinder head cover.
a Remove covers (1) and (2), bracket (3) and 6
cylinder head covers (4). For details, see
Disassembly and assembly volume, "Removal and installation of cylinder head assembly".

3. Remove inspection hole plug (5) from the front


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

30-14

4. When the No. 1 cylinder is at the compression


top dead center, adjust the valve clearance indicated by q of the valve layout plan.
a Loosen locknut (8) of adjustment screw (7),
insert feeler gauge D between crosshead (9)
and rocker arm (10), and rotate adjustment
screw (7) so that the feeler gauge will be
hitched a little.
a Valve clearance
q Air intake valve: 0.32 mm
q Exhaust valve: 0.62 mm
5. While fixing adjustment screw (7), tighten
lock-nut (8).
3 Locknut:
57.8 77.4 Nm {5.9 7.9 kgm}
a After tightening the lock nut, check the valve
clearance again.

D375A-6
(01)

DRAFT
Engine and cooling system
Adjusting valve clearance

6. Rotate the crackshaft forward one turn and


adjust the valve clearance indicated by Q of the
valve layout plan.
a The adjustment method is the same as
above.

7. After finishing adjustment, return the removedparts.


3 Cylinder head cover mounting bolt :
{No. 1, 3, 4, 5, 6 cylinders}
9.8 1.0 Nm {1.0 0.1 kgm}
{No.2 cylinder}
58.8 73.5 Nm {6 7.5 kgm}

D375A-6
(01)

30-15

DRAFT
Engine and cooling system
Measuring compression pressure

Measuring compression pressure


a Testing tools for compression pressure
Symbol
1
E

2
4

Part No.
795-502 1590
795-611-1220
6261-71-6150
795-799-5410
795-799-5420

Part name
Compression gauge
Adapter
Gasket
Adapter
Remover

a Remove the terminal on the injector side and


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

Stop the machine on level ground, lower the


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

a Insert the pin (indicated by the arrow) at the


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

3. Adjust the valve clearance of the cylinder to be


inspected. For details, see "Adjusting valve
clearance".
4. Disconnect fuel high-pressure tube (5) and
injector wiring harness (6).

30-16

D375A-6
(01)

DRAFT
Engine and cooling system
Measuring compression pressure

6. Install adapter E2 to the mounting hole on the


injector and the compression gauge E1.
a Fit the gasket to the injector end without fail
a Fix the adapter with the injector holder.
3 Holder mounting bolt :
58.8 73.5 Nm {6 7.5 kgm}
a Apply a little amount of engine oil to the connecting parts of the adapter and gauge so
that air will not leak easily.

7. Turn the starting switch to the ON position and


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

8. Rotate the engine with the starting motor and


test the compression pressure.
a Read the pressure gauge pointer when it is
stabilized.
9. After testing, remove measuring tools and reset
the machine to its original status.
a Install the injector and fuel high-pressure
tube according to the following procedure.
1) Install gasket (10) and O-rings (11) and (12).
a Take care not to install O-ring (11) to the
groove (b).
2 O-ring: Engine oil
D375A-6
(03)

2) Fit adaptor (9) to injector (8), and press it in


as a unit to the cylinder head by hand.

3) Install holder (7) and tighten bolt (13) and


washer (14) temporarily.
2 Spherical surface of washer: Engine
oil
4) Install the fuel high-pressure tube, and
temporarily tighten sleeve nut (5).
5) Fully tighten bolt (13).
3 Bolt:
58.8 73.5 Nm {6 7.5 kgm}
6) Fully tighten sleeve nut (5).
3 Sleeve nut :
39.2 - 44.1 Nm {4 - 4.5 kgm}

a Install the injector wiring harness according


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

30-17
30-21

DRAFT
Engine and cooling system
Measuring compression pressure

2) Fit spacer (16) and fix it with bolt (17).


3) Alternately tighten nuts (18) on the injector
side.
3 Nut:
2 0.2 Nm {0.2 0.02 kgm}

a Tighten the cylinder head cover mounting


bolt with the following torque.
3 Cylinder head cover mounting bolt :
{No. 1, 3, 4, 5, 6 cylinders}
9.8 1.0 Nm {1.0 0.1 kgm}
{No.2 cylinder}
58.8 - 73.5 Nm {6 - 7.5 kgm}

30-18

D375A-6
(01)

DRAFT
Engine and cooling system
Testing blow-by pressure

2. Testing for VHMS specifications


1) Turn the starting switch to the ON position
and switch the machine monitor to the "Pm
clinic" function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

2) Test the blowby pressure when the torque


converter is stalled at high idle speed.
a For the torque converter stall procedure,
see Step 3) and later in "6. Measuring
torque converter stall speed (Inspection
on Pm clinic screen)" of "Testing engine
speed".

30-24
30-20

D375A-6
(03)

DRAFT
Engine and cooling system
Testing engine oil pressure

Testing engine oil pressure


a Measuring tools for engine oil pressure
Symbol
1
G

3
4

Part No.
799-101-5002
790-261-1204
799-401-2320
799-101-5230
6215-81-9720

2. Measuring with oil pressure gauge


1) Open the engine left cover.
2) Remove oil pressure test plug (1).

Part name
Hydraulic tester
Digital hydraulic tester
Gauge
Nipple
O-ring

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.

a A nipple (quick coupler) is installed into the hydraulic oil inspection port of the engine for the
Pm clinic specification machine.
a Measure the engine oil pressure under the following condition.
q Engine oil temperature: Min. 70 C
q Engine coolant temperature: Within operating range
q Working mode: P-mode
q Gear shift mode: Manual
1. Checking with machine monitor (Pm clinic)
1) Turn the starting switch ON and set the
machine monitor to the "Pm clinic" function
display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

2) Run the engine and measure the engine oil


pressure at low idle and also at high idle.

D375A-6
(03)

3) Install nipple G3 and connect it to gauge G2.

4) Run the engine and measure the engine oil


pressure at low idle and also at high idle.

5) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

30-21
30-25

DRAFT
Engine and cooling system
Testing blow-by pressure

Testing blow-by pressure


a Measuring tools for blow-by pressure
Symbol
F
k

Part No.
799-201-1504

Part name
Blow-by checker

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.

3) Turn the starting switch to the ON position


and switch the machine monitor to the
"Adjustment" function display of the service
mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

a Measure the blow-by pressure under the following condition.


q Engine coolant temperature: Within operating range
q Power train oil temperature:
Within operating range
q Hydraulic oil temperature: 45 55 C
q Working mode: P-mode
q Gear shift mode: Manual
1. Testing with blowby kit
1) Open the engine left side cover and pull out
blow-by hose (1).
2) Install nozzle [1] and hose [2] of blowby
checker F to blowby hose (1) and connect
them to gauge [3].

D375A-6
(03)

4) Run the engine at high idle and test the


blow-by pressure when the torque converter
stalls.
a For the torque converter stall procedure,
see "5. Measuring torque converter stall
speed" of "Testing engine speed".
a Blow-by varies greatly according to the
condition of the engine. Therefore, if the
blow-by value is considered abnormal,
check for problems connected with defective blow-by, such as excessive oil consumption, defective exhaust gas color,
and prematurely dirty or deteriorated oil.
5) After finishing measuring, remove all test
tools in order to return the machine status as
it was.

30-19
30-23

Engine and cooling system


Testing EGR valve drive oil pressure

Testing EGR valve drive oil pressure

30-25

a Measuring instruments for EGR valve drive


pressure
Symbol

Part No.

799-101-5002
790-261-1204
795T-690-1110
G
4 01435-00835
07000-E2012
1

Part name
Hydraulic tester
Digital hydraulic tester
Block
Bolt
O-ring

Park the machine on a level ground and lower the work equipment and set firmly on the
ground, then set the parking brake lever and
work equipment lock lever to the LOCK position.

a Drive oil pressure for EGR valve will be checked


under the following condition.
q Engine oil temperature: 40 60 C
q Working mode: P-mode
q Gear shift mode: Manual

5. Install the nipple (component part of G1) into


measurement hole (a) (size: PT 1/8) of tool G4
and connect gauge [1] of hydraulic tester G1.
Reference: The oil pressure to be measured will
be a maximum of approximately 3 MPa
{30 kg/cm2}.

1. Open the left side cover.


2. Remove flange mounting bolts (2) and clamp
mounting bolt (3) of oil supply tube (1) that drives
the EGR valve on the EGR valve side.

3. Install tool G4 on the oil supply portion of the


EGR valve.
3 Mounting bolt (4) (component part of
G4):
27 34 Nm {2.8 3.5 kgm}
4. Install oil supply tube (1) that drives the EGR
valve on the top of tool G4 and tighten flange
mounting bolts (2) on the EGR valve side.
3 Flange mounting bolt (2):
27 34 Nm {2.8 3.5 kgm}

30-22

D375A-6
(06)

DRAFT
Engine and cooling system
Testing EGR valve and bypass valve drive oil pressure

6. Start the engine and measure the oil pressure at


low idle and high idle.

7. After testing, remove measuring tools and reset


the machine to its original status.
a Replace the flange O-ring on the EGR valve
side with new one.
3 Flange mounting bolt (2):
27 - 34 Nm {2.8 - 3.5 kgm}
3 Clamp mounting bolt (3):
58.8 - 73.5 Nm {6 - 7.5 kgm}

D375A-6
(01)

30-23

DRAFT
Engine and cooling system
Handling of fuel system devices

Handling of fuel system devices


a Precautions for checking and maintaining fuel
system
The common rail fuel injection system (CRI)
consists of more precise parts than the conventional fuel injection pump and nozzle. If foreign
matter enters this system, it can cause a trouble.
When testing and maintaining the fuel system,
take care more than the past. If dust, etc. sticks
to any part, wash that part thoroughly with clean
fuel.
a Precautions for replacing fuel filter cartridge
Be sure to use Komatsu genuine fuel filter
cartridge.
The fuel injection pump and nozzle of the
common rail type fuel injection system (CRI) are
consisted of more precision parts than those
used for the current pumps and nozzles. This
system, therefore, employs a special filter with
highly efficient filtering performance to prevent
mixing of foreign substances. Thus, substituting
it with a non-genuine filter could cause troubles
in the fuel system. It is strictly prohibited to use
such part.

30-24

D375A-6
(01)

DRAFT
Engine and cooling system
Releasing residual pressure from fuel system

Releasing residual pressure from


fuel system
a Pressure is generated in the low-pressure circuit
and high-pressure circuit of the fuel system while
the engine is running.
Low pressure circuit: Feed pump Fuel main
filter Fuel supply pump
High-pressure circuit: Fuel supply pump
Common rail Fuel injector
a The pressure in both low-pressure circuit and
high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is
stopped.
a Before the fuel circuit is tested and its parts are
removed, the residual pressure in the fuel circuit
must be released completely. Accordingly observe the following.
k Before testing the fuel system or removing
its parts, wait at least 30 seconds after stopping the engine until the residual pressure in
the fuel circuit is released. (Do not start the
work just after stopping the engine since
there is residual pressure.)

D375A-6
(01)

30-25

DRAFT
Engine and cooling system
Testing fuel pressure

Testing fuel pressure

3. Install nipple H3 and connect it to gauge H2.

a Measuring tools for fuel pressure


Symbol
1
H

Part No.

Part name

799-101-5002 Hydraulic tester


790-261-1204 Digital hydraulic tester
799-401-2320 Gauge
799-101-5160 Nipple (R 1/8)

795-471-1450 Adapter (M8 x 1.25)


07005-00812 Gasket

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.

a Test only the fuel pressure in the low-pressure


circuit from the feed pump through the engine
controller cooler and fuel filter to the supply
pump.
k Since the pressure in the high-pressure circuit from the supply pump through the common rail to the injector is very high, it cannot
be measured.
a Test the fuel pressure under the following conditions.
q Working mode: P-mode
q Gear shift mode: Manual

4. Start the engine and inspect the fuel pressure


with the engine running at high idle or at the
equivalent of rated output speed (stall load).
a If the fuel pressure is in the following range, it
is normal.
Engine speed
At high idle or at the
equivalent of rated output speed

Fuel pressure
0.15 0.3 MPa
{1.5 3 kg/cm2}

1. Open the engine left cover.


2. Remove plug (1).
5. After finishing measuring, remove all test tools in
order to return the machine status as it was.

30-30
30-26

D375A-6
(03)

DRAFT
Engine and cooling system
Handling of reduced cylinder mode operation

Handling of reduced cylinder


mode operation

Handling of no injection cranking


operation

a Reduced cylinder mode operation means to run


the engine with the fuel injectors of 1 or more cylinders disabled electrically to reduce the number
of effective cylinders. The purposes and effects
of this operation are as follows.

a No-injection cranking means to crank the engine


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

1. This operation is used to find out a cylinder


which does not output power normally (or,
combustion in it is abnormal).
2. When a cylinder is selected for the reduced
cylinder mode operation, if the engine speed and
output do not change from the normal operation
(all-cylinder operation), that cylinder has 1 or
more defects.
q Leakage through cylinder head gasket
q Defective injection
q Defective piston, piston ring, and cylinder liner
q Defective valve mechanism (Moving valve
system)
q Defect in electrical system
3. Since the common rail fuel injection system
controls the injector of each cylinder electronically, the operator can perform the cylinder cut
out mode operation easily with switches to find
out a defective cylinder.
a To implement reduced cylinder mode operation, see "Special functions of monitor panel
(EMMS)".
a Use the reduced cylinder mode for only the
purpose of troubleshooting.

D375A-6
(03)

30-27
30-31

DRAFT
Engine and cooling system
Testing leakage from pressure limiter and return rate from injector

Testing leakage from pressure limiter and return rate from injector

a Testing instruments for fuel return rate and leakage


Symbol
1
2
3
J

4
5
6

Part No.
6167-11-6640
6206-71-1770
Commercially
available
Commercially
available
Commercially
available
Commercially
available

Part name
Spacer
Joint

a Test the fuel return rate and leakage under the


following conditions.
q Working mode: P-mode
q Gear shift mode: Manual

Hose
Hose
Measuring cylinder
Stopwatch

a Prepare an oil pan of about 20 l to receive the oil


that will flow out during the testing process..
k

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.

30-28
30-32

D375A-6
(03)

DRAFT
Engine and cooling system
Testing leakage from pressure limiter and return rate from injector

1. Preparation work
1) Remove tube (3) between common rail (1)
and block (2).
2) Insert spacer J1 on block (2) side and tighten
the removed joint bolt again.
3 Joint bolt:
9.8 12.7 Nm {1.0 1.3 kgm}
a Fit the gaskets to both ends of the spacer.

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


tighten the currently removed joint bolt again.
3 Joint bolt:
17.7 22.6 Nm {1.8 2.3 kgm}
a Be sure to fit the gaskets to both ends of
the joint.
4) Connect inspection hose J3 to the tip of joint
J2.
a Bind the connecting part of the test hose
with a wire, etc. to prevent it from coming
off.
a The above is the preparation work for
testing the leakage from the pressure limiter.

2. Testing leakage from pressure limiter


1) Route inspection hose J3 in such that it may
be free from slack and then insert its end to
the oil pan (saucer).
2) Turn the starting switch to the ON position
and switch the machine monitor to "Adjustment" function display of the service mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

3) Run the engine at high idle and stall the


torque converter. After the engine speed is
stabilized, measure the return rate in 1
minute with measuring cylinder J5.
a For the torque converter stall procedure,
see "5. Measuring torque converter stall
speed" of "Testing engine speed".
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the leakage from the pressure limiter is
in the following range, it is normal.
Engine speed
(rpm)
Equivalent to rated operation

D375A-6
(03)

Leakage
(spill) (cc/min)
Max. 10

30-29
30-33

DRAFT
Engine and cooling system
Testing leakage from pressure limiter and return rate from injector

a For the torque converter stall procedure,


see "5. Measuring torque converter stall
speed" of "Testing engine speed".
a You may test for 20 seconds and judge by
multiplying the result by 3.
a If the supply pump is not supplying fuel,
the engine speed may not rise. In this
case, record the engine speed, too, during the test.
a If the return rate (spill) from the injector is
in the following range, it is normal.

4) After finishing testing, stop the engine.


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

2) Turn the starting switch to the ON position


and switch the machine monitor to "Adjustment" function display of the service mode.
q Adjustment code: 0530 (Stall mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

Engine speed
(Equivalent to rated output
operation load)
(rpm)
1,600
1,700
1,800
1,900
2,000

Return (Spill) limit


(spill) (cc/min)
960
1,020
1,080
1,140
1,200

4) After finishing testing, stop the engine.


4. Work after finishing testing
After finishing all testing, remove the testing
tools and return the removed parts.

3) Run the engine at high idle and stall the


torque converter. After the engine speed is
stabilized, measure the return rate in 1
minute with measuring cylinder J5.

30-34
30-30

D375A-6
(03)

DRAFT
Engine and cooling system
Bleeding air from fuel circuit

Bleeding air from fuel circuit


k

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Bleed air from the fuel circuit in the following cases according to this procedure.
q When the fuel filter is replaced
q When fuel is used up
q When the engine is started for the first time
after the fuel piping or supply pump is replaced
a When the fuel filter is replaced, don't feed fuel to
the filters, including both the main and pre-filter.
k While the electric priming pump is in operation, pressure is applied to the fuel circuit. Do
not loosen the air bleeding plug at this time,
since the fuel may spout out.
1. Set the starting switch to OFF position.

3. Open the engine left cover.


4. Open air bleeding valve (2).

5. Set electric priming pump switch (3) inside the


engine compartment to the "ON" position.
a Lamp (4) will start flashing and operation of
the electric priming pump will be started.

2. Check that supply valve (1) of the fuel tank is in


the "OPEN" position.

D375A-6
(01)

30-31

DRAFT
Engine and cooling system
Bleeding air from fuel circuit

a The built-in timer of this switch automatically


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

2) While the electric priming pump is operating,


crank the engine with the starting motor.
a If the engine does not start, wait for about
2 minutes and then repeat steps 1) and
2).
a Do not rotate the starting motor for more
than 20 seconds continuously.
3) If the engine starts, run it at low idle for 5
minutes to bleed all air from the fuel circuit.

6. After the specified time (about 7 minutes), lamp


(4) goes off automatically and the electric
priming pump stops.
a When the fuel filter alone was replaced,
above completes bleeding air..
7. When fuel is not provided in the fuel circuit such
as when run out of fuel occurred or when
replacement of the fuel pipe or supply pump was
done, set switch (3) to ON again after the electric priming pump is automatically stopped.
8. Bleeding air, in this case, completes as lamp (4)
went off.
9. Close air bleeding valve (2).
10. Start the engine with the starting motor.
a Do not rotate the starting motor for more than
20 seconds continuously.
a The air in the high-pressure circuit is bled automatically if the engine is cranked.
11. If the engine starts, run it at low idle for 5 minutes
to bleed all air from the fuel circuit.
a If the engine does not start, the air may have
not been bled from the low pressure circuit. In
this case, try to start the engine again according to the following procedure.
a Work with air bleeding valve (2) closed.
a If you failed to start the engine, wait for about
2 minutes and then try to start again.
1) Set electric priming pump switch (3) to the
"ON" position.

30-32

D375A-6
(01)

DRAFT
Engine and cooling system
Testing fuel circuit for leakage

Testing fuel circuit for leakage


k

Very high pressure is generated in the


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

8. Run the engine at high idle and load it.


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

2. Start the engine, keep its speed below 1,000


rpm, and stop it when its speed stabilizes.
3. Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color checker for
fuel leakage.
a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage.
4. Run the engine at low idle.
5. Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color checker for
fuel leakage.
a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage.
6. Run the engine at high idle.
7. Check the fuel piping and devices for fuel
leakage.
a Check mainly around the high-pressure circuit parts coated with the color checker for
fuel leakage.
a If fuel leakage is recognized, repeat the procedure from step 1 after repairing the leakage.

D375A-6
(01)

30-33

DRAFT
Engine and cooling system
Replacing and adjusting alternator and air conditioner compressor belt

Replacing and adjusting alternator and air conditioner compressor belt


k

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.

a The auto-tensioner is provided for the alternator


and air conditioner compressor belt. Thus, testing and adjustment of the belt is usually not necessary.
a Following describes the auto-tensioner adjustment procedure to be employed for the belt replacement.
1. Open the engine left side cover.
2. Loosen locknut (1), tighten push bolt (2) fully and
then loose in tension pulley (4).
3. Replace belt (5).
4. After replacing the belt, loosen push bolt (2) until
its installed length (a) is 90 mm.

5. Tighten locknut (1).

30-34

D375A-6
(01)

DRAFT
Engine and cooling system
Measuring fan speed

Measuring fan speed


k

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Measure the fan motor speed under the following condition.
q Hydraulic oil temperature: 45 55 C
q Working mode: P-mode
q Gear shift mode: Manual
1. Start the engine and set the machine monitor to
Adjusting function of the service mode.
q Adjustment ID: 1005 (Fan 100% mode)
a For the operating method, see "Special functions of machine monitor (EMMS)".
a If this adjustment code is displayed, the fan
speed is kept at 100% speed in accordance
with the engine speed, regardless of the
state of the machine.

2. While running the engine at low idle and high


idle, measure the fan speed
3. After finishing measurement, remove the
measuring instruments and return the removed
parts.
a If the starting switch is turned to the OFF position, the fan 100% mode is reset.

D375A-6
(01)

30-35

DRAFT
Engine and cooling system
Testing fan circuit oil pressure

Testing fan circuit oil pressure


a Testing instruments for fan circuit oil pressure
Symbol
1
S

2
4
6

Part No.
799-101-5002
790-261-1204
790-301-1330
07372-21055
07000-13035

Part name
Hydraulic tester
Digital hydraulic tester
q Flange
Bolt
O-ring

4. Install nipple [2] of hydraulic tester S1 and


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

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Test the fan circuit oil pressure under the following condition.
q Hydraulic oil temperature: 45 55C
q Working mode: P-mode
q Gear shift mode: Manual
1. Open the radiator mask.
2. Remove bolt (1) and disconnect tube (2).

5. Start the engine and switch the machine monitor


to "Adjustment" function display of the service
mode.
q Adjustment ID: 1005 (Fan 100% mode)
a For the operating method, see "Special functions of machine monitor (EMMS)".
a If this adjustment code is displayed, the fan
speed is kept at 100% speed in accordance
with the engine speed, regardless of the
state of the machine.

3. Install oil pressure testing flange S2 and then


install tube (2) again with bolt S3.
q The stem of oil pressure testing bolt S3 is 15
mm longer.
6. While running the engine at high idle, measure
the fan circuit oil pressure.
7. After measuring, remove measuring tools and
reset the machine to its original status.

30-36

D375A-6
(01)

DRAFT
Engine and cooling system
Bleeding air from fan pump

Bleeding air from fan pump


a If the fan pump is removed and installed or its
piping is disconnected and connected, bleed air
from the pump case according to the following
procedure.
a Before bleeding air, check that the hydraulic oil
level is proper.
1. Remove the floor mat.
2. Remove left footrest (1).

3. Loosen air bleeders (2) and (3), and leave them


for 15 minutes.

4. After 15 minutes, run the engine at low idle.


5. When oil flows from air bleeders, tighten air
bleeders (2) and (3).

D375A-6
(01)

30-37

DRAFT
Engine and cooling system
Adjusting fuel control dial and decelerator pedal

Adjusting fuel control dial and decelerator pedal

1. Outline of fuel control system


q The following signals are inputted as rotation
command signals to the engine controller.
q Decelerator pedal potentiometer signal
q 3rd throttle signal
The engine controller controls the fuel control
system of the engine (CRI system) according
to the lowest engine speed signal among
those input signals.
q Adjust the deceleration slow speed by adjusting the decelerator pedal linkage.

30-42
30-38

[1] Fuel control dial (2nd throttle signal)


[2] Engine controller
[3] Power train controller
[4] Decelerator pedal (1st throttle signal)
[5] Decelerator potentiometer
[6] Engine (CRI system)
[7] Machine control signal (3rd throttle signal)
[8] Rod
2. Preparation work
a Set the working mode to P mode and set the
gear shift mode to Manual.
1) Start the engine and switch the machine
monitor to "Pm clinic" function display of the
service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

D375A-6
(03)

DRAFT
Engine and cooling system
Adjusting fuel control dial and decelerator pedal

3. Adjusting the speed when using decelerator


pedal
With the fuel control dial in the high idle position,
depress decelerator pedal (4) until it touches the
stopper. Check that the engine speed is normal
under this condition.
q Engine speed: 900 50 rpm
a If the engine is not running at the correct
speed, adjust installed dimension (a) of rod
(8).
q Standard installed dimension (a) of rod: 123
mm (reference)
4. Adjusting high idle speed
Return the decelerator pedal, set the fuel control
dial to the high idle position, and check that the
engine is running at the correct high idle speed.
q High idle speed: 1,900 (0/-50) rpm
a If the high idle speed is abnormal, adjust it
according to the following procedure.
q If the engine speed is high:
To remove the play of the decelerator pedal,
use stopper bolt (9) to adjust the engine
speed to less than 1,800 rpm, then adjust to
the high idle speed.
q If the engine speed is low:
Use stopper bolt (9) to adjust to the high idle
speed.
5. After finishing all adjustment, return the removed
parts.

D375A-6
(03)

30-39
30-43

Power train
Testing power train oil pressure

Power train

30-4

Testing power train oil pressure

30-4

a Testing tools for power train oil pressure


Symbol
K

1
3

Part No.
Part name
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester
799-401-2320 Gauge

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Test the power train oil pressure under the following condition.
q Power train oil temperature: Within operating
range
q Working mode: P mode
q Gear shift mode: Manual
a The power train oil pressure pickup ports (centralized oil pressure pickup ports) are located inside the inspection window cover on the left
outside of the operator's cab.

No. Mark

14

RB

15

LUB

Oil pressure to check


Right steering brake pressure
Output pressure of sudden
stop prevention valve
Transmission lubricating
oil pressure

Gauge
(MPa {kg/cm2})
6 {60}

1.0 {10}

a Table of pressure pick-up port positions and


gauges to use
No. Mark
1

IN

OUT

LU

SC

T/M

FWD

REV

1ST

2ND

10

3RD

11

LC

12

LB

13

RC

30-40

Oil pressure to check


Torque converter inlet
pressure
Torque converter outlet
pressure
Torque converter lock-up
clutch pressure
Torque converter stator
clutch pressure
Transmission main relief
pressure
Transmission F clutch
pressure
Transmission R clutch
pressure
Transmission 1st clutch
pressure
Transmission 2nd clutch
pressure
Transmission 3rd clutch
pressure
Left steering clutch pressure
Left steering brake pressure
Output pressure of sudden
stop prevention valve
Right steering clutch pressure

Gauge
(MPa {kg/cm2})
2.5 {25}
1.0 {10}
2.5 {25}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}
6 {60}

6 {60}

6 {60}

D375A-6
(06)

Power train
Testing power train oil pressure

1. Testring torque converter inlet pressure (IN)


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

2. Testing torque converter outlet pressure


(OUT)
(Testing with oil pressure gauge)
1) Connect gauge K2 to oil pressure test nipple
(2).

2) Start the engine and set the PCCS lever in


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

2) Start the engine and set the PCCS lever in


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

4) After finishing testing, remove all test tools in


order to return the machine status as it was.

4) After finishing testing, remove all test tools in


order to return the machine status as it was.

D375A-6
(06)

30-41

DRAFT
Power train
Testing power train oil pressure

3. Measuring torque converter inlet pressure


and outlet pressure
[Checking with machine monitor (Pm clinic)]
1) Turn the starting switch to the ON position
and switch the machine monitor to the "Pm
clinic" function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

2) Start the engine and set the PCCS lever in


the fully neutral position.
a The test may be performed with the parking brake lever in the LOCK position.
3) While running the engine at low idle and high
idle, measure the inlet pressure and outlet
pressure of the torque converter.

30-46
30-41-1

D375A-6
(03)

DRAFT
Power train
Testing power train oil pressure

D375A-6
(03)

30-41-2
30-47

DRAFT
Power train
Testing power train oil pressure

4. Testing torque converter lock-up clutch


pressure (LU)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (3).
a For an analog oil pressure gauge, the
pressure must be 2.5 MPa {25 kg/cm2}.

3) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Automatic gear shift
q Preset range: F2-R2
4) With the brake pedal depressed, set the
PCCS lever to F and the gear speed to the
2nd.
5) Gradually release the brake pedal.
6) With the decelerator pedal depressed, set
the fuel control dial to the MAX position.
7) Gradually release the decelerator pedal and
raise the engine speed.
8) Test the torque converter lock-up clutch
pressure when the engine speed reaches
near the high idle.
a The test cannot be made at a low engine
speed.
9) After finishing measuring, remove all test
tools in order to return the machine status as
it was.

2) Start the engine, set the machine monitor to


"Adjusting" function of the service mode, and
disengage both steering clutches.
q Adjustment ID:
5535 (Both steering clutch disengage
mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)"
section.

30-48
30-42

D375A-6
(03)

DRAFT
Power train
Testing power train oil pressure

5. Testing torque converter stator clutch pressure (SC)


1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (4).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

2) Start the engine and set the PCCS lever in


the fully neutral position.
a The test may be performed with the parking brake lever in the LOCK position.
3) Test the torque converter stator clutch pressure with the engine at low idle and high idle.

4) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

D375A-6
(03)

6. Testing transmission main relief pressure


(T/M)
[Testing using oil pressure gauge]
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (5).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

2) Start the engine and set the PCCS lever in


the fully neutral position.
a The test may be performed with the parking brake lever in the LOCK position.
3) Test the transmission main relief pressure
with the engine at low idle and high idle.

4) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

30-43
30-49

DRAFT
Power train
Testing power train oil pressure

[Checking with machine monitor (for VHMS


specification)]
1) Turn the starting switch to the ON position
and switch the machine monitor to the "Pm
clinic" function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

2) Start the engine and set the PCCS lever in


the fully neutral position.
a The test may be performed with the parking brake lever in the LOCK position.
3) Test the transmission main relief pressure
with the engine at low idle and high idle.

30-50
30-43-1

D375A-6
(03)

DRAFT
Power train
Testing power train oil pressure

D375A-6
(03)

30-43-2
30-51

DRAFT
Power train
Testing power train oil pressure

7. Testing transmission F clutch pressure


(FWD)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure pickup plug (6).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

7) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjustment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset range: F1-R1
5) While pressing the brake pedal, set the direction of PCCS lever in the forward position.
a Keep the steering unit in neutral.
a Check that [F1] is displayed in the gear
speed display section.
6) Check the F clutch pressure with the engine
at low and high idle.
30-52
30-44

D375A-6
(03)

DRAFT
Power train
Testing power train oil pressure

8. Testing transmission R clutch pressure


(REV)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to nipple (7) for checking oil pressure.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

6) Check the R clutch pressure with the engine


at low and high idle.

7) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjustment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset range: F1-R1
5) While pressing the brake pedal, set the
PCCS lever in the backward position.
a Keep the steering unit in neutral.
a Check that [R1] is displayed in the gear
speed display section.

D375A-6
(03)

30-45
30-53

DRAFT
Power train
Testing power train oil pressure

9. Testing transmission 1st clutch pressure


(1st)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to nipple (8) for checking oil pressure.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

6) Check the 1st clutch pressure with the


engine at low and high idle.

7) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjustment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset range: F1-R1
5) While pressing the brake pedal, set the direction of PCCS lever in the forward position.
a Keep the steering unit in neutral.
a Check that [F1] is displayed in the gear
speed display section.

30-54
30-46

D375A-6
(03)

DRAFT
Power train
Testing power train oil pressure

10. Testing transmission 2nd clutch pressure


(2nd)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to nipple (9) for checking oil pressure.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

6) Check the 2nd clutch pressure with the


engine at low and high idle.

7) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjustment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset range: F1-R1
5) While pressing the brake pedal, set the direction of PCCS lever in the forward position and
shift the gear to 2nd using the shiftup switch.
a Keep the steering unit in neutral.
a Check that [F2] is displayed in the gear
speed display section.
D375A-6
(03)

30-47
30-55

DRAFT
Power train
Testing power train oil pressure

11. Testing transmission 3rd clutch pressure


(3rd)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to nipple (10) for checking oil pressure.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

6) Check the 3rd clutch pressure with the


engine at low and high idle.

7) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

2) Start the engine and set the parking brake


lever in the FREE position.
3) Switch the machine monitor to the "Adjustment" function display of the service mode
and disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special
functions of machine monitor (EMMS)".

4) Set the gearshift mode and preset range as


follows with the gearshift mode selector
switch and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset range: F1-R1
5) While pressing the brake pedal, set the direction of PCCS lever in the forward position and
shift the gear to 3rd using the shiftup switch.
a Keep the steering unit in neutral.
a Check that [F3] is displayed in the gear
speed display section.
30-56
30-48

D375A-6
(03)

DRAFT
Power train
Testing power train oil pressure

12. Testing left steering clutch pressure (LC)


1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (11).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

13. Testing left steering brake pressure (LB)


1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (12).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

2) Start the engine and set the parking brake


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

2) Start the engine and set the parking brake


lever in the FREE position.
3) Test the left steering brake pressure with the
engine at low idle and high idle.
a Check that the oil pressure becomes 0
when the PCCS lever steering is operated fully to the left.
a Check that the oil pressure becomes 0
when the brake pedal is depressed fully
or the parking brake lever is operated to
the LOCK position.

5) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

D375A-6
(03)

4) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

30-49
30-57

DRAFT
Power train
Testing power train oil pressure

14. Testing right steering clutch pressure (RC)


1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (13).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

15. Testing right steering brake pressure (RB)


1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure test nipple (14).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

2) Start the engine and set the parking brake


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

2) Start the engine and set the parking brake


lever in the FREE position.
3) Test the right steering brake pressure with
the engine at low idle and high idle.
a Check that the oil pressure becomes 0
when the PCCS lever steering is operated fully to the right.
a Check that the oil pressure becomes 0
when the brake pedal is depressed fully
or the parking brake lever is operated to
the LOCK position.

5) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

30-58
30-50

4) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

D375A-6
(03)

DRAFT
Power train
Testing power train oil pressure

16. Testing transmission lubrication pressure


1) Connect gauge K2 to oil pressure test nipple
(15).

17. Testing of output pressure of sudden stop


prevention valve (Sudden stop prevention
valve operation mode)
1) Connect oil pressure gauge [1] of hydraulic
tester K1 to oil pressure pickup nipples (12)
and (14).
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.
q (12): For steering left brake

2) Start the engine and test the transmission


lubricating pressure with the engine at high
idle.

(14): For steering right brake

3) After finishing measuring, remove all test


tools in order to return the machine status as
it was.
2) Start the engine, switch the machine monitor
to "Adjusting" function of the service mode
and deactivate the sudden stop prevention
valve and right and left brake ECMV.
q Adjustment ID: 9996 (Sudden stop prevention valve operation mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)"
section.

D375A-6
(03)

30-51
30-59

DRAFT
Power train
Testing power train oil pressure

3) Set the parking brake lever in the FREE position and set the PCCS lever in the ALL
NEUTRAL position.
4) Test the output pressure of the sudden stop
prevention valve with the engine at low idle.
a If the output pressure of the sudden stop
prevention valve is as follows, it is normal.
2
q 1.13 1.57 MPa {11.5 16.0 kg/cm }

5) After finishing measuring, remove all test


tools in order to return the machine status as
it was.

30-60
30-51-1

D375A-6
(03)

DRAFT
Power train
Testing power train oil pressure

D375A-6
(03)

30-51-2
30-61

DRAFT
Power train
Adjusting transmission output speed sensor

Adjusting transmission output speed sensor


k

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.

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


a Take care that the speed sensor is not
dragged.
3 Nut: 49.0 68.6 Nm {5 7 kgm}

1. Remove cover (1) under the fuel tank.

7. After finishing adjustment, return the removed


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

8. Start the engine, set the machine monitor to


"Adjusting" function of the service mode, and
disengage both steering clutches.
q Adjustment ID:
5535 (Disengage mode for both steering
clutches)
a For the operating method, see "Special functions of machine monitor (EMMS)".
a Set the working mode to P mode and set the
gear shift mode to Manual.
9. Operate the PCCS lever in the direction of
forward or reverse position, and check the transmission speed is displayed normally.

3. Look through the sensor mounting hole and


check that a tooth tip of gear (3) is at the center
of the hole.
a If the tooth tip is not at the center of the hole,
adjust it by starting the engine and moving
the machine forward or in reverse.
4. Screw in sensor (2) until its tip lightly touches the
tooth tip of gear (3).
2 Threads of sensor: Gasket sealant (LG-5)
5. Return sensor (2) by 1/2 - 1 turn.
a Clearance (a) between the sensor tip and
gear tooth tip becomes 0.75 1.50 mm.
30-52

D375A-6
(01)

DRAFT
Power train
Simple test procedure for brake performance

Simple test procedure for brake


performance
k

Since the torque converter is stalled, keep


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

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Carry out the simple performance test of the
brake under the following condition.
q Power train oil temperature:
Within operating range
1. Set the blade and ripper in the travel posture on
a level place.

2. Start the engine and set the parking brake lever


in the FREE position.
3. Set the gearshift mode and preset range as
follows with the gearshift mode selector switch
and shiftup or shiftdown switch.
q Gear shift mode: Manual gear shift
q Preset range: F2-R2
4. While pressing the brake pedal, set the direction
of PCCS lever in the forward position.
k If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd
gear speed.
a Check that [F2] is displayed in the gear
speed display section.
a Keep the steering unit in neutral.
5. Press the decelerator pedal and set the fuel
control dial in the high idle (MAX) position.
6. Return the decelerator pedal slowly and check
that the machine does not start when the engine
speed reaches the high idle speed.

D375A-6
(03)

30-53
30-63

DRAFT
Power train
Adjusting brake pedal and parking brake lever

Adjusting brake pedal and parking brake lever


Adjusting brake pedal

Adjusting parking brake lever

30-54

D375A-6
(01)

DRAFT
Power train
Adjusting brake pedal and parking brake lever

Adjusting brake pedal


1. Adjusting travel of brake pedal
Adjust installation dimension b of stopper bolt (2)
so that the travel of brake pedal (1) is dimension
a.
a When adjusting the travel of the brake pedal,
disconnect the brake rod from the pedal.
q Pedal stroke a: 75 mm
q Stopper bolt installation dimension b: 42 mm
2. Adjusting installed length of brake rod
1) Keep the parking brake lever in the release
position.
2) Install brake rod (3) and release brake pedal
(1) (do not depress it).
3) Adjust installed dimensions c and d of brake
rod (3) with turnbuckle (5) so that the spool of
brake valve (4) is at the OFF position.
a The locknut of the turnbuckle has a
left-handed thread (reverse thread) at the
brake pedal end.
q Stopper bolt installation dimension c: 32
mm
q Stopper bolt installation dimension d: 14
mm
3 Locknut:
34.3 58.8 Nm {3.5 6.0 kgm}
4) Check that clearance x between yoke (12)
and pin (13) is approximately 1 mm.

5. Checking brake oil pressure


1) Start the engine and switch the machine
monitor to the "Adjustment" function display
of the service mode.
q Adjustment ID: 9995 (Control brake release mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a The function of this mode is used to cancel electrical control of brake oil pressure
and makes it possible to check the brake
oil pressure mechanically.
a Set the working mode to P mode and set
the gear shift mode to Manual.

3. Checking travel of brake pedal


1) Depress brake pedal (1) and check that the
travel is as given in Step 1 above.
2) Depress brake pedal (1) and check that the
pedal is stopped by stopper (6).
3) Check that spool travel e of brake valve (4) is
within the correct range when brake pedal (1)
is depressed.
q Spool travel e: 19 23 mm
4. Adjusting brake potentiometer
Turn the starting switch ON and set the machine
monitor to Adjusting function of the service
mode.
q Adjustment ID: 0005
(Brake pedal potentiometer initial correction)
a For the operating method, see "Special functions of machine monitor (EMMS)".
a Set the working mode to P mode and set the
gear shift mode to Manual.

D375A-6
(03)

2) With the parking brake lever in the FREE


position, depress the brake pedal fully and
check that the brake oil pressure on both
sides of left and right becomes 0.98 MPa {10
kg/cm2} or less.
a For details of the method of testing the
brake oil pressure, see "Testing power
train oil pressure".
a When the brake pedal is depressed, if the
brake oil pressure does not drop below
0.98 MPa {10 kg/cm2}, adjust its linkage
again.

30-55
30-65

DRAFT
Power train
Adjusting brake pedal and parking brake lever

a If the linkage is adjusted normally, the


brake pedal potentiometer may be adjusted wrongly or broken. (Adjust the potentiometer only when necessary.)

a Set the working mode to P mode and set


the gear shift mode to Manual.

Adjusting parking brake lever side


1. Assembly and installation of lever assembly
1) Assemble lever assembly (7) and adjust the
operation of limit switch (8).
a When assembling the lever assembly,
disconnect the parking cable from the lever.
q Lever raised: OFF, lever lowered: ON
q Operation stroke of limit switch: 3 mm
2) Install lever assembly (7).
2. Adjusting installed length of parking brake
cable
1) Connect parking brake cable (9) to the lever
and valve, then adjust installed dimensions f
f and g.
q Cable installation dimension (f): 112.8
mm
q Cable installation dimension (g): 114.0
mm
2) Operate parking brake lever (10) between
the free and lock positions, and adjust rod
end (4) so that spool stroke h of brake valve
(11) is normal.
q Spool stroke (h): 23.0 mm
3) Check that clearance y between rod end (11)
and pin (14) is approximately 0.5 mm.
a When tightening the lock nuts of brake yoke
(12) and rod end (11), exercise care so that
the yoke and rod end will not interfere with
pins (13) and (14).
q The operating effort of the parking brake
lever may increase.

2) Check that the limit switch signal is input


normally when parking brake lever (10) is set
in the FREE position and LOCK position.
q FREE position:
Travel lock NC OFF, Travel lock NO ON
q LOCK position:
Travel lock NC ON, Travel lock NO OFF

3. Checking brake oil pressure


Start the engine, set the parking brake lever in
the FREE position and LOCK position, and
check that the brake oil pressure becomes as
follows at the respective positions.
a For details of the method of testing the brake
oil pressure, see "Testing power train oil
pressure".
2
q LOCK position: 0 MPa {0 kg/cm }, FREE position: Specified pressure
4. Checking limit switch
1) Turn the starting switch ON and set the
machine monitor to Monitoring function of the
service mode.
q Monitoring code: 40905 (P/T SW Input 3)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
30-66
30-56

D375A-6
(03)

Power train
Adjusting position of pccs lever console

Adjusting position of pccs lever console

30-6

1. Set operators seat (1) facing the front (dozing


position).
2. In this condition, check that console (2) is
parallel to operators seat (1).
a If it is not parallel, adjust installed dimension
(a) of rod (3).
q Standard installed dimension (a): 179 mm
(Machine with operator's seat isolator: 178.5 mm)
a The locknut at the rear of the turnbuckle has
a left-handed thread (reverse thread)

D375A-6
(07)

30-57

Power train
Emergency escape method when there is failure in power train

Emergency escape method when


there is failure in power train
30-67
a Tools for emergency escape
Symbol
L

Part No.
19M-06-32820
1 7824-66-6430
195-06-71220
2 790-190-1601

Part name
Switch assembly
Resistor
Wiring harness
Pump assembly

1. Emergency escape method using switch box


(Use L1)
a If the machine cannot be moved because of
a trouble in the electrical system of the power
train control unit (travel direction, gear range,
steering), retreive the situation according to
the following procedure.
a With this procedure, it is necessary to be able
to start the engine. If the engine will not start,
see "Emergency escape method using brake
release device".
1) Connect switch assembly [1] and resistor [2]
to wiring harness [3] of emergency escape
device L1.
k Resistor [2] controls the drive voltage
of the solenoid, so connect it before
connecting the wiring harness to the
machine.
k In order to prevent mistaken actuation,
set all the gear speed switches of
switch assembly [1] to the OFF position and the directional switch to the P
position.

2) Open the inspection cover on the left fender


and connect wiring harness [3] to PL1
connector (1) and PL2 connector (2).
q PL1 connector (1): Connect to male and
female ends

30-58

PL2 connector (2): Connect to male end


a The female end of connector PL2 remains disconnected, so cover it with vinyl.
a Insert switch assembly [1] inside the cab
through the cab window.

3) Disconnect the neutral safety relay (NSF)


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

4) Start the engine and set the parking brake


lever in the FREE position.

D375A-6
(06)

Power train
Emergency escape method when there is failure in power train

5) Operate switch assembly [1] and move the


machine to a safe place.
a The gear speed switch has an electric circuit that gives priority to operation of the
low speed switch.
k Take care that the L.H. and R.H. steering directions are opposite when reverse.

2. Emergency escape method with brake


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

2) Install volume pump [4] of pump assembly L2


to the outside of the operators cab.

D375A-6
(06)

3) Remove the fuel tank undercover and


disconnect supply hose (3) of the pin puller
solenoid valve.

4) Connect end hose of pump assembly L2 to


the supply hose. (Use the nipple of face seal
type.)
a Block the solenoid valve side with plug.
Plug: 02789-00315
5) Turn the starting switch ON and set the
parking brake lever in the FREE position.
6) Operate the vacuum pump to raise the brake
releasing oil pressure to the initial pressure.
2
q Initial pressure: 2.74 MPa {28 kg/cm }
a Since an accumulator is installed in the
circuit, the handle must be operated 30 50 times to raise the oil pressure.
a If the oil pressure does not rise above a
certain level, the relief valve may be set to
low pressure. In this case, adjust the set
pressure of the relief valve.
7) Tow the machine to a safe place.
a The brake releasing oil pressure lowers
gradually because of internal leakage and
the brake is applied again approximately
one minute after. Therefore, work quickly.
a When the brake release oil pressure
drops to about 1.57 MPa {16 kg/cm2}, the
brake is applied. In such a case, increase
the brake release oil pressure to its initial
level by operating the vacuum pump
again.

30-59

DRAFT
Undercarriage and frame
Inspecting wear of sprocket

Undercarriage and frame


Inspecting wear of sprocket
a Use the "Full-scale dimensions drawing of
sprocket profile" in "Sprocket" in "maintenance
standard" as a gauge for testing wear of the
sprocket.
a Make a copy of the "Full-scale dimensions drawing of sprocket profile" on a transparent paper or
sheet and apply it directly to the sprocket to see
if the sprocket can be used.

30-60

D375A-6
(01)

DRAFT
Undercarriage and frame
Testing and adjusting track shoe tension

Testing and adjusting track shoe tension


Testing
1. Drive the machine forward and stop on a horizontal surface.
a Stop the machine without using the brake.
2. Put straight steel rod (1) on top of the track
between the idler and front carrier roller, and test
clearance (a) from the bottom of the steel rod to
the track shoe grouser.
q Standard clearance (a): 20 30 mm

2. If tension is too high:


Loosen plug (3) and release some of the grease.
k There is danger that the plug may fly out
under the high internal pressure of the
grease, so never loosen the plug more
than 1 turn.
3 Plug: 59 88 Nm {6 9 kgm}
3. If tension is too low:
Pump in grease through grease fitting (4).
a If the track shoe is not tensed well, drive the
machine forward and in reverse slowly.
a After finishing adjustment, check the tension
again according to the above procedure.

Adjustment
a If the track shoe tension is abnormal, adjust it according to the following procedure.
1. Remove cover (2).

D375A-6
(01)

30-61

DRAFT
Hydraulic system
Measuring and adjusting work equipment oil pressure

Hydraulic system
Measuring and adjusting work
equipment oil pressure
a Measuring and adjusting instruments for work
equipment oil pressure
Symbol
1
M
2

Part No.
799-101-5002
790-261-1204
799-101-5220
07002-11023

Part name
Hydraulic tester
Digital hydraulic tester
Nipple (10 1.25 mm)
O-ring

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Open the cover of the main control valve (both
sides).
Testing
a Measure the work equipment oil pressure under
the following condition.
q Hydraulic oil temperature: 45 55C
q Working mode: P-mode
q Gear shift mode: Manual
a The unload pressure, work equipment oil pressure can be checked with the monitoring function of the service mode of the machine monitor
(See 3).

3) Run the engine at high idle and set the blade


control lever and ripper control lever in
neutral and measure the unload pressure.
a The work equipment lock lever may be
set in the LOCK position.
k Do not operate the work equipment
when analog oil pressure gauge (6
MPa {60 kg/cm2}) is mounted. (This is
required to protect the gauge from being damaged.)

1. Measuring unload pressure


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

4) After finishing measuring, remove all test


tools in order to return the machine status as
it was.
2. Measuring work equipment oil pressure
1) Remove P oil pressure pickup plug (1) and
LS oil pressure pickup plug (2) from the
control valve.
2) Mount nipple M2, and connect it to oil pressure gauge [1] of hydraulic tester M1.
a When using an analog oil pressure
gauge, use one of 6 MPa {60 kg/cm2}.

30-72
30-62

D375A-6
(03)

DRAFT
Hydraulic system
Measuring and adjusting work equipment oil pressure

2) Mount nipple M2, and connect it to oil pressure gauge [1] of hydraulic tester M1.
a When using analog oil pressure gauges,
use ones of 40 MPa {400 kg/cm2}.

5) After finishing measuring, remove all test


tools in order to return the machine status as
it was.
3. Testing using machine monitor (Pm clinic)
1) Turn the starting switch to the ON position
and switch the machine monitor to the "Pm
clinic" function display of the service mode.
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a The VHMS specification is shown as an
example in the figure.

3) Start the engine and set the work equipment


lock lever in the free position.
4) Run the engine at high idle, operate the blade
control lever and ripper control lever to
relieve each cylinder at a stroke end, and
measure the work equipment relief pressure
and work equipment LS relief pressure.
a The work equipment relief oil pressure is
displayed at P stamp side (plug-1 side),
but work equipment LS relief oil pressure
is displayed at LS stamp side (plug-2
side).

D375A-6
(03)

2) Start the engine and measure each oil pressure.


a The measuring condition of each oil pressure is the same with 1 2 above.
a Hydraulic pressure displayed at P stamp
side of control valve can be measured,
but hydraulic pressure at LS stamp side
(work equipment LS relief pressure) cannot be measured.

30-63
30-73

DRAFT
Hydraulic system
Measuring and adjusting work equipment oil pressure

Adjustment
1. Adjusting unload pressure
a The unload pressure cannot be adjusted.

4) After finishing measurement, check the work


equipment oil pressure according to the
above measuring method.

2. Adjusting work equipment oil pressure


a If the work equipment oil pressure is abnormal, adjust it with work equipment LS relief
valve (3) according to the following procedure.
a This figure shows a dual tilt model, 6-spool
valve. (The single tilt model has a 5-spool
valve.)

1) While fixing adjustment nut (4), loosen


locknut (5).
2) Adjust the pressure by rotating adjustment
nut (4).
a If the adjustment nut is
q rotated to the right, the pressure is
heightened.
q rotated to the left, the pressure is lowered.
a Quantity of adjustment per turn of adjustment nut:
Approx. 19.6 MPa {200 kg/cm2}
3) While fixing adjustment nut (4), tighten
locknut (5).
3 Locknut: 39 49 Nm {4 5 kgm}

30-74
30-64

D375A-6
(03)

DRAFT
Hydraulic system
Testing control circuit main pressure

Testing control circuit main pressure


Tools for testing control circuit main pressure
Symbol
M

Part No.
Part name
799 - 101 - 5002 Hydraulic tester
1
790 - 261 - 1204 Digital hydraulic tester

4. After finishing measurement, remove the


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

Testing
k

Stop the machine on level ground, lower the work


equipment to the ground, stop the engine, and set
the parking brake lever and work equipment lock
lever in the lock position.

a Test the control circuit main pressure under the


following conditions.
q Hydraulic oil temperature: 45 55C

1. Open the cover of the main control valve (both


sides).
2. Connect oil pressure gauge [1] of hydraulic
tester M1.
a When using an analog oil pressure gauge,
use one of 6 MPa {60 kg/cm2}.
a Inspection nipple (1) is equipped.

3. Start the engine, run it at high idle, and test the


oil pressure when the blade lever and ripper
lever are placed at the HOLD position.

D375A-6
(01)

30-65

DRAFT
Hydraulic system
Testing PPC valve output pressure

Testing PPC valve output pressure


a Tools for testing PPC valve output pressure
Symbol
N
k

Part No.
Part name
799-101-5002 Hydraulic tester
790-261-1204 Digital hydraulic tester

Stop the machine on level ground, lower the work


equipment to the ground, stop the engine, and set
the parking brake lever and work equipment lock
lever in the lock position.

a Check that the control circuit oil pressure is correct before testing the PPC valve output pressure.
a Test the PPC valve output pressure under the
following conditions.
q Hydraulic oil temperature: 45 55C

4. Start the engine and set the work equipment lock


lever in the Free position.
5. Run the engine at high idle, operate the control
lever of the circuit to be tested, and test the oil
pressure.
a Operate the control lever fully when testing.
a For blade LOWER, operate to the FLOAT position.
6. After finishing measurement, remove the
measuring tools and return the removed parts.

1. Open the cover of the main control valve (both


sides).
2. Remove the oil pressure switch (1) of the circuit
to be tested.
a For details of the position to be tested, see
the drawing on the next page.

3. Fit nipple [1] (R1/8) of hydraulic tester N1, then


connect to oil pressure gauge [2].
a When using an analog oil pressure gauge,
use one of 6 MPa {60 kg/cm2}.

30-66

D375A-6
(01)

DRAFT
Hydraulic system
Testing PPC valve output pressure

A. Blade RAISE
B. Blade TILT (Right)
C. Blade LOWER
D. Blade TILT (Left)

D375A-6
(01)

E. Ripper TILT (In)


F. Ripper RAISE
G. Ripper TILT (Back)
H. Ripper LOWER

30-67

DRAFT
Hydraulic system
Adjusting play of PPC valve

Adjusting play of PPC valve


a If there is excessive play at the tip of the ripper
lever and blade lever, adjust the PPC valve as
follows.
a The diagram shows the PPC valve for the ripper.
q Standard play (a):
1 - 6 mm at the position 400 mm away from lever
rotation center
(both to front and rear, and to left and right)
q Standard play (b): 0.03 0.30 mm (full stroke)
a Exchange the joint (4) when lever end play is
longer than 24 mm at neutral position must be
joint may have damaged.
1. Remove boot (1).
2. Loosen locknut (2) and rotate disc (3) to adjust
the amount of play.
a Do not move the pistons at this time.
3. Secure disc (3) in position and tighten locknut
(2).
3 Lock nut: 69 88 Nm {7 9 kgm}
4. Apply grease (G2-LI) to sliding area of joint (4)
and to contact area of disc and piston.
2 Sliding area of the joint: G2-LI
2 Contact area of the disc and piston: G2-LI
5. Install boot (1).

30-78
30-68

D375A-6
(03)

DRAFT
Hydraulic system
Testing output pressure of ripper pin-puller solenoid valve

Testing output pressure of ripper pin-puller solenoid valve


a Tools for testing output pressure of ripper
pin-puller solenoid valve
Symbol
1
P
2

Part No.
Part name
799 - 101 - 5002 Hydraulic tester
790 - 261 - 1204 Digital type hydraulic tester
Oil pressure pickup adapter
799 - 401 - 3200
(03 size)

Stop the machine on level ground, lower the


work equipment completely to the ground,
then set the parking brake lever and work
equipment lock lever to the LOCK position.
a Test the output pressure of the ripper pin puller
solenoid valve under the following conditions.
q Power train oil temperature:
Within operating range

4. Start the engine, run at high idle, and test the oil
pressure when the ripper pin-puller switch is
actuated.

1. Disconnect pin-puller cylinder hoses (1) and (2).

2. Fit adapter P2, then connect the hoses again.

5. After completing the test remove the testing


equipment and set to the original condition.

3. Fit nipple P1 of hydraulic tester [1], then connect


oil pressure gauge [2].
a Use a 6 MPa {60 kg/cm2} oil pressure gauge.

D375A-6
(01)

30-69

DRAFT
Hydraulic system
Checking location of cause of hydraulic drift of blade and ripper

Checking location of cause of


hydraulic drift of blade and ripper
a If hydraulic drift occurs in the blade or ripper,
check as follows to see if the cause is in the cylinder packing or in the control valve.
1. Set the cylinder to be inspected to the following
posture, then stop the engine.
1) Blade lift cylinder
Push the blade against the ground to raise
the front of the chassis.
a The blade lift cylinder has a built-in piston
valve, so do not operate the cylinder to
the end of the stroke.

2) Blade tilt cylinder


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

3) Ripper lift cylinder


Push the ripper against the ground to raise
the rear of the chassis.

30-80
30-70

2. Operate the control lever in the direction to


extend the cylinder rod, and check the movement of the cylinder.
q If the downward movement becomes faster,
the packing is defective.
q If there is no change, the control valve is defective.
a If there is no more pressure in the accumulator, run the engine for approx. 10 seconds to
charge the accumulator.
[Reference:] If the cause of the hydraulic drift is
in the packing, the speed of downward movement in the above operation will become faster
for the following reasons.
1) When the work equipment is set to the
posture given above, (holding pressure
applied to the bottom end), oil will leak from
the bottom end to the head end. However,
the volume at the head end is smaller than at
the bottom end (by an amount proportional to
the volume of the rod), so if the oil flows in
from the bottom end, the internal pressure at
the head end will rise.
2) If the internal pressure at the head end rises,
a balance will be made in proportion to this at
a certain pressure (this differs according to
the amount of leakage). When the pressure
becomes balanced, the speed of downward
movement becomes slower.
3) In this condition, if the lever is operated as
shown above, the circuit at the head end is
connected to the drain circuit (the bottom end
is closed by a check valve), and the oil at the
head end flows to the drain circuit. As a
result, the balance is lost and the speed of
downward movement increases.)

D375A-6
(03)

DRAFT
Hydraulic system
Testing leakage inside work equipment cylinder

Testing leakage inside work equipment cylinder


a Tools for testing leakage from work equipment
cylinder
Symbol
L

Part No.
Commercially
available

Part name
Measuring cylinder

a Test the oil leakage inside the hydraulic cylinder


under the following conditions.
q Hydraulic oil temperature: 45 55C
a The blade lift cylinder has a built-in piston valve,
so the internal leakage cannot be tested.

3. Run the engine at high idle and apply the relief


pressure to the bottom end of the cylinder.
q Blade tilt cylinder: Extract the cylinder to be
tested
q Ripper lift cylinder: Lower ripper
q Ripper tilt cylinder: Tilt ripper to front
4. Wait for 30 seconds, then test the amount of
leakage over the next 1 minute.
5. After finishing measurement, return the removed
parts.

1. Fully extend the cylinder to be tested, and set to


the test posture.
1) Blade tilt cylinder
Extract the cylinder to be tested to the stroke
end.
2) Ripper lift cylinder
Pull out the shank pin and lower the ripper to
the end.
3) Ripper tilt cylinder
Tilt the ripper fully to the front.
2. Disconnect hose on the cylinder head side and
block the hose side with a plug.
a Remove the hose cover of the blade tilt cylinder.
k Take care not to disconnect the hose on
the bottom side.

D375A-6
(01)

30-71

DRAFT
Hydraulic system
Releasing remaining pressure in work equipment cylinders

Releasing remaining pressure


in work equipment cylinders

Bleeding air from work equipment


cylinders

a When disconnecting the piping between the control valve and work equipment cylinder, release
the residual pressure in the circuit according to
the following procedure.

a If the work equipment cylinder was removed and


installed or its piping was disconnected and connected, bleed air from its circuit according to the
following procedure.

1. Start the engine, and lower the blade and ripper


to the ground.

1. Run the engine at low idle for about five minutes.

2. Stop the engine.


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

2. Running the engine at low idle, extend and


retract the cylinder to be bled 4 5 times.
a Stop the piston rod about 100 mm before the
end of the stroke. Never operate it to the relief position.
3. Running the engine at high idle and carry out the
operation in 2.
4. Running the engine at low idle, move the
cylinder to the stroke end to relieve the oil.

5. Fully close the oil filler cap of hydraulic tank.

30-82
30-72

D375A-6
(03)

DRAFT
Hydraulic system
Adjusting ripper lever position

Adjusting ripper lever position

a Use the following procedure to adjust the ripper


lever to the optimum position.
a It is possible to adjust the position of the ripper
lever within a range of 40 mm to the front and
rear of the center of the lever shaft.
1. Adjusting within range of 40 mm from center
to rear
1) Loosen lock bolt (1).
2) Set lever (2) to the optimum position.
3) Tighten lock bolt (1) to hold lever (2) in position.
2. Adjusting within range of 40 mm from center
to front
1) Loosen lock bolt (1).
2) Remove lever (2) and turn it 180 .
3) Install lever(2) to lever (5), then set it to the
optimum position.
4) Tighten lock bolt (1) to hold lever (2) in position.
5) Loosen nut (3).
6) Turn knob (4) 180 .
7) Tighten nut (3) to hold knob (4) in position.

D375A-6
(03)

30-73
30-83

DRAFT
Work equipment
Adjusting work equipment lock lever

Work equipment
Adjusting work equipment lock lever

Stop the machine on level ground, lower the


work equipment to the ground, stop the engine, and set the parking brake lever and
work equipment lock lever in the lock position.
a Tighten the locknut of the rod securely and bend
the cotter pin securely.
a Remove the control valve cover.

a For the operating method, see "Special functions of machine monitor (EMMS)".
a Set the working mode to P mode and set the
gear shift mode to Manual.

1. Set work equipment lock lever (1) in the LOCK


position.
2. Set and install limit switch (2) to sliding surface
(a) of lever (3).
a Just set the roller of the limit switch to the
sliding surface. Do not move it.
3. Set work equipment lock lever (1) in the FREE
position and check that limit switch (2) operates
normally.
q Stroke of limit switch: 2.5 3 mm
4. Turn the starting switch ON and set the machine
monitor to Monitoring function of the service
mode.
a Monitoring code:
70300 (Blade Sw Input)

30-84
30-74

5. Check that the limit switch signal is input


normally when work equipment lock lever (1) is
set in the FREE position and LOCK position.
q FREE position:
Work equipment lock NC OFF, Work equipment lock NO ON
q LOCK position:
Work equipment lock NC ON, Work equipment lock NO OFF
D375A-6
(03)

DRAFT
Work equipment
Adjusting blade

Adjusting blade

a If the blade has been removed or disassembled,


adjust as follows.
1. Procedure for adjusting with shims when assembling
1) Use shims to adjust the clearance at center
portion (1) and (2).
Adjustment
location
1
2

Adjusted
clearance

Standard
clearance

Standard
shim thickness

a
b

See Note

4.5 mm

Note: Adjust so that the play of the ball at the


spherical portion in the axial direction is
within 1 mm. Check that the ball rotates
smoothly.

D375A-6
(01)

30-75

DRAFT
Work equipment
Adjusting blade

2) Use shims to adjust the clearance at trunnion


portion (3).
AdjustAdjusted
ment locacleartion
ance
3

Standard clearance

Standard
shim thickness

1.56 0.65 mm
Total clearance

12 mm

2. Adjusting blade tilt


(Only single tilt specification machine)
1) Adjust installation dimension (d) of brace (4)
with the handle.
q Dimension (d) of installed brace: 1,587
mm
2) Test left and right tilt (e1) and (e2).
[Semi-U dozer]
q Right tilt (e1): Approx. 770 mm
q Left tilt (e2): Approx. 770 mm
[Full-U dozer]
q Right tilt (el): Approx. 840 mm
q Left tilt (el): Approx. 840 mm
3) If the tilt is not the same on the left and right
sides, adjust installation dimension (d) of
brace (4) as follows to give the same tilt on
both sides.
q (e1) > (e2): Carry out fine adjustment to
make installation dimension d longer
q (e1) < (e2): Carry out fine adjustment to
make installation dimension d shorter

30-76

D375A-6
(01)

DRAFT
Cab and its attachments
Testing and adjusting operator's cab

Cab and its attachments


Testing and adjusting operator's cab
Check after installing cab assembly
1. Testing pressure in cab
a Test the operator's cab according to the following conditions.
q Engine speed: High idle
q Blower speed: High (Hi)
q Fresh/Recirculation switch: Fresh air position
1) Start the engine and switch the machine
monitor to "Adjustment" function display of
the service mode.
q Adjustment code: 1005 (Fan 100% mode)
a For the operating method, see "Special
functions of machine monitor (EMMS)".
a If this adjustment code is displayed, the
fan speed is kept at 100% speed in accordance with the engine speed, regardless
of the state of the machine.

a Secure the end of hose [1] to the operator's seat with tape.

6) Seal the mounting holes of lock lever (1) with


tape (2).
2) Prepare a transparent vinyl hose.
q Outside diameter: 10 mm,
Length: 3000 mm
3) Secure the inside end of the hose to the top
of the back seat with a tape.
4) Pour coolant in the hose up to about half.
5) Remove slide glass lever lock (1) and insert
the other end of vinyl hose [1].

D375A-6
(01)

30-77

DRAFT
Cab and its attachments
Testing and adjusting operator's cab

7) Set the coolant level in the vinyl hose out of


the cab to that in the cab.
8) Run the engine at high idle and test coolant
level difference (c).
a [a] side: Inside of cab (Pressurized)
[b] side: Out of cab (Atmospheric pressure)
q Criteria
Measuring value (c) X 8 mm {0.08 kPa {8
mmH2O})
a If the tested value is lower than the standard value, check the following.
q Plug of control box
q Clogging of air filters (recirculation
and fresh air filters) in the air conditioner
q Seals between the cab and the floor
frame

2. Check of sealing performance


1) Close the all openings of the cab.
2) Throw water onto the area near the cab
(hatched area) at a rate of about 19 l/min for
10 minutes.
q At this time, it is not necessary to splash
pressurized coolant.
3) Splash coolant horizontally from a hose over
sealing surface (3).
4) Check around the dashboard carefully.
a If coolant leaks, caulk the leaking part and
check again.

30-88
30-78

D375A-6
(03)

DRAFT
Cab and its attachments
Testing and adjusting operator's cab

3. Testing and adjusting door lock


Close the door and check the relationship
between the operator's cab and door. If there is
any fault, repair it.
1) Check the installed height of damper rubber
(4).
(Check both sides, 4 pieces on each)
q Stick adhesive tape [1] to the contact face
of damper rubber (4), open and close the
door 2 3 times. Then, check the contact
face of adhesive tape [1] against the operator's cab.
Normal:
When the door is closed, the damper
rubbers come in contact lightly.
Abnormal:
When the door is closed, the damper
rubbers do not come in contact or come in
contact so strongly that the adhesive
tapes are removed.

D375A-6
(03)

2) Check the relationship between the door


latch and striker (on both sides).
q Close door (5) and check the engaging
condition of latch (6) and striker (7).
q Normal:
Deviation (a) is 0.5 mm or less.
a Check deviation (a) between latch center
(y) and striker center (x) from (A) direction.

30-79
30-89

DRAFT
Cab and its attachments
Testing and adjusting operator's cab

3) Adjusting height of damper rubber


q Loosen the mounting bolt of damper rubber (4).
q The shim can be removed or installed
without removing the mounting bolt.
q Increase or decrease the number of shim
(8) installed at the bottom of damper rubber (4) to properly adjust the height of
damper rubber (4).

a Open the door and check the engaging condition of the open latch and
striker.
q Check that the claw of open latch (9)
does not ride over the bent part of
striker (10).
q Check that the body of open latch (9)
does not interfere with striker (10).
4) Adjusting height of latch and striker
1] Temporarily tighten the mounting bolt of
striker (7), open and close the door 2 - 3
times to align latch (6) and striker (7) to
each other.
2] Check the engaging condition of latch (6)
and striker (7).
3] Securely tighten the mounting bolt of
striker (7).
4] Open and close the door and check that it
is locked and unlocked smoothly. If the
door is not locked and unlocked smoothly
(if the knob is heavy), perform the adjustment procedure from the first.
a Operating effort of door unlock lever:
68.6 19.6 N {7 2 kg}
5) Apply grease (G2-LI) to latch (6).
a If latch (6) is not sufficiently greased, the
knob becomes heavy.
4. Testing open lock
Lock the door open and check the relationship
between the operator cab and door. If there is
any fault, repair it.
1) Check of condition
1] Check the relationship between open lock
latch (9) and striker (10) from the direction
of (B).

30-90
30-80

2] Check the installed height of the stopper


rubbers.
(Check both sides, 2 pieces on each.)
q Lock the door open and shake it in the
forward and reverse directions to see
if it has any play.
q Check that the operating effort of unlock lever is not heavy.

D375A-6
(03)

DRAFT
Cab and its attachments
Testing and adjusting operator's cab

2) Adjusting
1] Adjusting latch and striker
q Loosen the adjustment nut of striker
(10) and adjust striker (10) so that it
will not interfere with or ride over open
latch (9), then tighten the nut.
q If interference cannot be eliminated by
adjusting striker (10), loosen the
mounting bolt of open latch (9) and
adjust open latch (9).
q Push the door. If it moves until clearance (b) between striker (10) and
open latch (9) is reduced to "0", loosen
mounting nut (12) of stopper rubber
(11) and extend stopper rubber (11) in
the pushing direction to adjust.

D375A-6
(01)

2] Adjusting installed height of stopper


rubber
1] Loosen locknut (12) of stopper rubber
(11).
2] If there is any play, adjust stopper
rubber (11) until dimension (c) is as
follows.
a If the door is not locked easily or the
unlock lever is heavy, return stopper
rubber (11) in the range that the door
does not have any play.
q Dimension (c) of stopper rubber
above cab:
35 0.5 mm
q Dimension (c) of stopper rubber under
cab:
32 0.5 mm
q Operating effort of door unlock lever:
68.6 19.6 Nm {7 2 kgm}
3] After adjusting, tighten locknut (12).

30-81

Cab and its attachments


Testing and adjusting operator's seat isolator

Testing and adjusting operator's seat isolator


a Machine with operator's seat isolator

30-87

3) Stand backrest (4) of the operator's seat


upright.

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

2) Pull turning lever (2) and rotate turntable (3)


by 13 degrees.
4) Open window (5) on the left side of the operator's cab.

30-81-1

D375A-6
(07)

Cab and its attachments


Testing and adjusting operator's seat isolator

5) Press the seat surface through the window.

2. Oil leakage from damper


q Criterion: No oil leakage from damper.
a When the criterion is not satisfied.
q Replace the operator's seat isolator assembly.

D375A-6
(07)

1) Remove bolts (7) of front cover (6) of the


operator's seat and remove the front cover.

2) Check damper (8) for oil leakage.

30-81-2

Cab and its attachments


Testing and adjusting operator's seat isolator

3. Breakage of stopper rubber


q Criterion: The stopper must not come off.
a When the criterion is not satisfied.
q Replace the operator's seat isolator assembly.
1) Put your feet on foot rest (9) and brace your
legs.

2) Check that stopper (10) touches stopper


rubber (11) and does not the steel portion.

30-81-3

D375A-6
(07)

Cab and its attachments


Testing and adjusting operator's seat isolator

D375A-6
(07)

30-81-4

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Electrial system
Special functions of machine monitor (EMMS)

30-82

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Upper section of machine monitor (Display section)

(a): Multi-display
a The figure shows an example of display of symbols and gauges in the ordinary display mode
(The contents of display depend on the condition
of the machine and operating method).
a When the engine is started, the battery voltage
may lower suddenly, depending on the ambient
temperature and the condition of the battery.
In this case, the machine monitor goes off for a
moment. This phenomenon is not a failure,
however.
Upper section of machine monitor (Switch section)
[F1]: F1 function switch
[F2]: F2 function switch
[F3]: F3 function switch
[F4]: F4 function switch
[F5]: F5 function switch
[F6]: F6 function switch
a The function of each function switch is indicated
by graphic mark in the multi-display (a) above
that function switch.
a If the graphic mark of a function switch is not displayed, that function switch is not working.
Lower section of machine monitor (Switch section)

[1]: Numeral 1 input switch/Operation mode selector


switch
[2]: Numeral 2 input switch/Gearshift mode selector
switch
[3]: Numeral 3 input switch/Customize switch
[4]: Numeral 4 input switch/Buzzer cancel switch
[5]: Numeral 5 input switch
[6]: Numeral 6 input switch/Customize memory
switch
[7]: Numeral 7 input switch
[8]: Numeral 8 input switch
[9]: Numeral 9 input switch
[0]: Numeral 0 input switch
Switch having no numerals: Unused
a Each switch has the function indicated by graphic mark and the function of inputting a numeral.
a The machine monitor automatically judges
which function of each switch is currently effective, according to the display condition of
multi-display (a).

D375A-6
(01)

30-83

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

t Ordinary functions and special functions of machine monitor


The machine monitor has the ordinary function and special functions and displays information of various types
on the multi-display
Some items are displayed automatically according to the internal setting of the machine monitor and the others are displayed according to the operation of the switches.
1. Ordinary functions: Operator mode
The items in this mode are displayed ordinarily. The operator can display and set them by operating the
switches (Display and setting of some items need special operations of the switches).
2. Special functions: Service mode
The items in this mode are not displayed ordinarily. Each serviceman can display them by operating the
switches specially.
This mode is used for special setting, testing, adjusting, or troubleshooting.

Display of KOMATSU logo

Page
30-85
30-85

Display of check before starting

30-85

Display of warning after check before starting

30-86

A
A
A
A
B

Display of ending of maintenance interval


Display of check of preset
Display of ordinary screen
Display of end screen
Selection of operation mode

30-86
30-86
30-87
30-87
30-87

Selection of gearshift mode

30-87

B
B
B

Customizing operation
Operation of customize memory
Operation to cancel alarm buzzer
Selection of dual tilt
(Dual tilt specification)

30-88
30-88
30-88

B
B
B
B
B
C
C

D
D
D

Operation to display camera mode (if camera is installed)


Operation to display clock and service
Check of maintenance information
Setting and display of user mode
Display of caution monitor
Display function of action code and failure
code
O (Special operation)
Function of checking display of LCD (Liquid
Crystal Display)
Function of checking service meter
Function of changing maintenance password

page
30-94
30-95

Service mode
01 Monitoring
02 Abnormality
Record

Mechanical system "Abnormality Record"

30-100

Electrical system "Abnormal30-101


ity Record"

03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-on Mode
Unit
Setting of maintenance pass06 Default
word
Setting of camera
Setting of ECO display
07 Adjustment

30-103
30-104
30-105
30-107
30-108

08 PM clinic

30-131

30-88

09 Cylinder Cut-Out

30-133

30-89
30-89
30-89
30-90

10 No Injection
11 Fuel Consumption
12 Display of saved load
13 Setting of VHMS

30-134
30-136
30-137
30-138

30-90

14 Snap shot (Machine equipped with VHMS)

30-138

30-88

OSpecial operations

Operator mode (Outline)

30-109
30-110
30-111
30-112

30-92
30-92
30-93

a Classification of operator mode


A: Display/Function from time when starting switch is turned ON to time when screen changes to ordinary
screen and display after starting switch is turned OFF
B: Display/Function when switch of machine monitor is operated
C: Display/Function when certain condition is satisfied
D: Display/Function which needs special operation of switch

30-84

D375A-6
(01)

Electrical system
Special functions of machine monitor (EMMS)

t Operator mode (Outline)


30-95
a Only outline of the operator mode is described in
this section.
For details of contents/operation of each function/display, see "the Structure, function and
maintenance standard, or Operation and Maintenance Manual".
a The following are the displays or functions of the
operator mode explained in this section (including some items which need special operations).

30-95
Display of KOMATSU logo
When starting switch is turned ON, KOMATSU logo
is displayed for 2 seconds.
After the KOMATSU logo is displayed for two seconds, the screen changes to "Password input (if
password is set)" screen , or "Check before starting"
screen.

Display pattern
a b c d
1 1 1 1
2 2 2 2

Display of KOMATSU logo


Display of check before starting
Display of warning after check
3
before starting
Display of ending of maintenance
3
interval
Display of check of preset
3 3 4 4
Display of ordinary screen
4 4 5 5
Display of end screen
Selection of operation mode
Selection of gearshift mode
Customizing operation
Operation of customize memory
Operation to cancel alarm buzzer
Selection of dual tilt (Dual tilt specification)
Operation to display camera mode (if camera is
installed)
Operation to display clock and service meter
Check of maintenance information
Setting and display of user mode
Display of caution monitor
Action code and failure code display function
O (Special operation)
Function of checking display of LCD (Liquid Crystal
Display)
Function of checking service meter
Function of changing maintenance password

Display of check before starting

When the screen changes to the check-before-starting screen, the check before starting is carried out
for 2 seconds.
a If any abnormality is detected by the check before starting, the screen changes to "Display of
warning after check before starting" or "Display
of ending of maintenance interval".
a If no abnormality is detected by the check before
starting, the screen changes to "Display of check
of preset".
a The monitors (3 pieces) displayed on the screen
are the items under the check before starting.

a Display pattern of operator mode


The contents of display from the time when
starting switch is turned ON to time when screen
changes to ordinary screen depends on the
setting and condition of the machine.
a: When engine start lock is set effective
b: When engine start lock is set ineffective
c: When there is abnormal item in
check-before-starting items
d: When there is maintenance item which is not
maintained after specified interval

D375A-6
(06)

30-85

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Display of warning after check before starting

Display of ending of maintenance interval

If any abnormality is detected by the check before


starting, the warning monitor is displayed on the
screen.
a The following figure shows that the radiator coolant level monitor (a) is warning of low radiator
coolant level.

When the check before starting is carried out, if a


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

Display of check of preset

If the check before starting is finished normally, the


screen to check the preset (gear speed at start) is
displayed for 2 seconds.
a After display of check of preset is finished, the
screen changes to "Display of ordinary screen".

30-86

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Display of ordinary screen

Selection of operation mode

If the machine monitor starts normally, the ordinary


screen is displayed.
a Service meter (a) or a clock is displayed at the
center upper section of the screen (The service
meter or clock is selected with [F4]).
a Power train oil temperature gauge (b) is displayed on the multi-gauge section (It is turned
ON and OFF with the user mode function or
[F2]).
a ECO gauge (c) is displayed at the right end of
the screen (It is turned ON and OFF in the service mode).

While the ordinary screen is displayed, press the operation mode selector switch, and the operation
mode monitor (a) changes.
a Each time the switch is pressed, the operation
mode changes between [P (Power)] and [E
(Economy)].

Selection of gearshift mode

Display of end screen

When the starting switch is turned OFF, the end


screen is displayed for 5 seconds.

D375A-6
(03)

While the ordinary screen is displayed, press the


gearshift mode selector switch, and the gearshift
mode monitor (a) in the gear speed display section
changes.
a Each time the switch is pressed, the gearshift
mode changes among [Automatic gearshift],
[Manual gearshift] and [Shoe slip control] (Optional) in order.
a If the automatic gearshift mode is selected, "AUTO" symbol (b) is displayed in the gear speed
display section. If the manual gearshift mode or
shoe slip control mode is selected, "MAN" symbol is displayed.

30-87
30-97

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Customizing operation

Selection of dual tilt (Dual tilt specification)

While the ordinary screen is displayed, press the


customize switch, and you can change the setting of
the machine.
a If the customize memory switch is operated
while the above screen is displayed, up to 5 settings can be saved.

Select the blade dual tilt mode by changing the


blade control lever knob switch while the ordinary
screen is displayed.
a If the dual tilt mode is turned ON, dual tilt mode
monitor (a) is displayed. If the former is turned
OFF, the latter is put out.

Operation of customize memory

Operation to display camera mode (if camera is installed)

While the ordinary screen is displayed, press the


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

Operation to cancel alarm buzzer


While the alarm buzzer is sounding, if the buzzer
cancel switch is pressed, the alarm buzzer stops.
a Even if the buzzer cancel switch is pressed, the
screen does not change.

30-88

When a camera is installed, if [F3] is pressed, the


multi-display changes to the camera image.
a Set the connection of the camera in the service
mode.

a Up to 3 cameras can be connected. If the camera mode is selected, however, only the image of
camera 1 is always displayed.

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

a If a caution is generated in the camera mode, the


caution monitor is displayed at the left upper of
the screen.
a When an error that there is a user code occurs in
the camera mode, if the machine stops for 10
seconds, the screen changes to the ordinary
screen and displays the error information.
a When two or more cameras are connected, the
image of one of them or the images of two of
them can be displayed.
a If 2-camera image display [F4] is selected, the
image of camera 1 is displayed on the left side of
the screen and the image of camera 2 is displayed on the right side. The image of camera 3
is displayed only singly.
a If the images of 2 cameras are displayed simultaneously, images are displayed at intervals of 1
second on the right and left screen.
Operation to display clock and service meter

While the ordinary screen is displayed, press [F4],


and section (a) changes to the service meter and
clock alternately.
a When the clock is selected, adjust the time, set
12-hour or 24-hour display, and set the summer
time with the user mode function.
a Display of service meter

Check of maintenance information

While the maintenance monitor or ordinary screen is


displayed, press [F5], and the maintenance table
screen is displayed.

a To reset the time left after finishing maintenance,


more operations are necessary.
(See "Maintenance history" section in service
mode)

Setting and display of user mode

While the ordinary screen is displayed, press [F6],


and the user menu screen is displayed.

a Display of clock

D375A-6
(03)

30-89
30-99

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

a There are following items in the user menu.


Utility screen select
Multi gauge select
Screen adjustment
Time adjustment
Language setting
Reverse interlock selection mode
Fan reverse mode
Prelub skip

Display of action code and failure code

If an abnormality which displays an action code and


a failure code occurs on the ordinary screen or camera mode screen, all the information of the abnormality is displayed.
(a): Action code (3 digits)
(b): Failure code (5 or 6 digits)
(c): Telephone mark
(d): Telephone No.
a This screen is displayed only when an abnormality (failure code) for which a user code is set occurs.
a The telephone mark and telephone No. are displayed only when the telephone No. is registered
in the service mode.
a If multiple abnormalities occur simultaneously,
all the codes are displayed repeatedly in order.
a Since the information of the displayed failure
code is recorded in the fault history in the service
mode, check the details in the service mode.

Display of caution monitor

If an abnormality which displays a caution monitor


occurs on the ordinary screen or camera mode
screen, the caution monitor is displayed large for a
moment and then displayed at (a) in the screen.
a On the camera mode screen, the caution monitor flashes at the left upper of the screen when
the caution is generated.

30-90

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

a Remedies given by displayed action codes to operator to take are as follows (Excerpt from the Operation
and Maintenance Manual).
Action
code

Method of indicating trouble

Examples of trouble

Remedy given to operator to take


q

E01

Action code and failure


code are displayed.

q
q

Backup alarm does not sound.


Fan speed is always at maximum.

q
q

q
q

E02
q

Action code and failure


code are displayed.
Alarm buzzer sounds.

q
q

q
q

E03

q
q

Action code and failure


code are displayed.
Telephone No. is displayed (if set).
Alarm buzzer sounds.

q
q
q
q
q

E04

q
q

D375A-6
(03)

Action code and failure


code are displayed.
Telephone No. is displayed (if set).
Alarm buzzer sounds.

q
q
q

Gear is not shifted up or down.


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

q
q

q
q

Although all or a part of automatic


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

Move machine to safe place.


Ask your Komatsu distributor for repair.

Stop machine immediately.


Ask your Komatsu distributor for repair.

30-91
30-101

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Function of checking display of LCD (Liquid Crystal


Display)

While the ordinary screen is displayed, if the following numeral input switch and function switch are operated as follows, all the LCD (Liquid Crystal
Display) lights up in white.
q Operation of switches (simultaneous): [4] + [F2]
a When finishing the operation of the switches, release [F2] first.
a If there is a display error in the LCD, only that
part is indicated in black.
a The LCD panel sometimes has black points
(points which are not lighted) and bright points
(points which do not go off) for the reason of its
characteristics.
If the number of the bright points and black
points does not exceed 10, those points are not
a failure or a defect.
a To return to the former screen, press the function
switch.

30-92

Function of checking service meter

To check the service meter while the starting switch


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

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Function of changing maintenance password

When changing the maintenance password used for


the maintenance setting function, follow these procedures.

q
q

(If it has only 3 or less digits or has 7 or more


digits, it is not accepted).
[F5]: Delete input numeral/Return to ordinary
screen
[F6]: Confirm input numeral

1. While the ordinary screen is displayed, perform


the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4 ]+ [5]o [5] o [5]
a This operation of the switches is not accepted until 10 minutes pass after the starting
switch is turned on.

2. After the "Password" screen is displayed, input


the current password with the numeral input
switches and confirm it with the function switch.
q [F5]: Delete input numeral/Return to ordinary
screen
q [F6]: Confirm input numeral
a Default password: [000000]
a If the input password is correct, the screen
changes to the next screen.
a If the input password is incorrect, the message to input the password again is displayed.

4. After the "New Password" screen is displayed


again, input a new password again with the
numeral input switches and confirm it with the
function switch.
q [F5]: Delete input numeral/Return to ordinary
screen
q [F6]: Confirm input numeral
a If a password different from the password input before is input, the message to input
again is displayed.

5. If the screen to notify completion of setting is


displayed and then the ordinary screen is
displayed, the password is changed successfully

3. After the New password input screen is


displayed, input a new password with the
numeral input switches and confirm it with the
function switch.
a Set a new password of 4 6 digits
D375A-6
(01)

30-93

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

t Service mode
To change the operator mode to the service mode,
perform the following operation.
This operation is always required when you use the
service mode.
1. Check of display of screen and operation of
switches
While the ordinary screen is displayed, perform
the following operation with the numeral input
switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4]+[1]o[2]o[3]
a This operation of the switches is accepted
only while the ordinary screen is displayed.

a The items which can be selected in the service menu are as follows.
01 Monitoring
Mechanical system "Abnormality Record"
Electrical system "Abnormality Record"
03 Maintenance Record
04 Maintenance Mode Change
05 Phone Number Entry
Key-on Mode
Setting of unit
Setting of maintenance pass06 Default
word
Setting of camera
Setting of ECO display
07 Adjustment
08 PM clinic
09 Cylinder Cut-Out
10 No Injection
11 Fuel Consumption
12 Display of saved load
13 Setting of VHMS
14 Snap shot (Machine equipped with VHMS)
02 Abnormality
Record

a Items with 2-digit codes are the menus displayed on the Service menu screen. The
items on their right are the menus on the next
hierarchy.

2. Selection of the service menu


When the "Service Menu" screen is displayed,
the service mode is selected. Select a service
menu you use with the function switches or
numeral input switches.
q [F3]: Move to lower menu
q [F4]: Move to upper menu
q [F5]: Return to ordinary screen (operator
mode)
q [F6]: Confirm selection
a You may enter a 2-digit code with the numeral input switches to select the menu of that
code and confirm it with [F6].

30-94

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Monitoring

The machine monitor can monitor the condition of


the machine in real time by receiving signals from
various switches, sensors, and actuators installed to
many parts of the machine and the information from
the controllers which are controlling switches, etc.
1. Selecting menu
Select "01 Monitoring" on the "Service Menu"
screen.

2. Selecting monitoring items


After the "Monitoring selection menu screen" is
displayed, select items to be monitored with the
function switches or numeral input switches.
q [F1]: Go to next page (screen)
q [F2]: Go to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Delete input numeral/Return to service
menu screen
q [F6]: Confirm selection
a Selection with function switches: Select an
item with [F3] or [F4] and confirm it with [F6].
a Selection with numeral input switches: Enter
a 5-digit code, and the item of that code is selected directly. Confirm that item with [F6].
a If the color of the selected box changes from
yellow to red, selection of the item of that box
is confirmed.
a Up to 6 monitoring items can be selected at a
time. You may not able to set up to 6 items,
however, depending on the display form of
those items.

D375A-6
(01)

3. Deciding monitoring items


After selecting monitoring items, execute monitoring with the function switch or numeral input
switch.
a Execution with function switch: Doubleclick
or hold down [F6] (about 2 seconds).
a Execution with numeral input switch: Input
[99999] and press [F6].
a When monitoring only 2 items, for example,
select them and confirm with [F6]. If [F6] is
pressed once more at this time, monitoring is
executed.
a If monitoring items are selected up to the limit
number, monitoring is executed automatically.

30-95

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

4. Executing monitoring
After the "Executing monitoring screen" is
displayed, perform the necessary operation of
the machine and check the monitoring information.
a Monitoring information is indicated by value,
ON/OFF, or special display.
a The unit of display can be set to SI unit, metric unit, or inch unit with the Default function
in the service mode.

6. Changing machine setting mode


To change the setting of the "P/E Mode", "Fan
Rev." mode, or "Working" mode during monitoring, operate the corresponding switch under
the current condition, and the mode setting
screen is displayed.
While this screen is displayed, if the corresponding switch is operated further, the corresponding mode is changed.
a After finishing changing the setting, press
[F6] to MPareturn to the monitoring information screen.
a If the setting is changed during monitoring,
the new setting is held even after the screen
returns to the ordinary screen after monitoring is finished.

5. Holding monitoring information


The monitoring information can be held and
reset with the function switches.
q [F3]: Reset holding
q [F4]: Hold (displayed data)
q [F5]: Return to monitoring selection menu
screen

30-96

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Monitoring items list


Code
No.
50300
50301
50400
31619
31618
90600
90601
31628
32900
60100
60600
03001
03000

31521

50200
50201
31622
31616
31612
31613
31614
30100
31400
32601
32602
32603
32604
31642
90700
40001
60000
70200
31624
10000

40905

40906

31520

Monitoring item (displayed on screen)


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

D375A-6
(03)

Unit (Default: SI)


SI

Metric

mV
mV
mV
mA
mA
mA
mA
mA

mV
mV
%
mV

mV
mV
mV
mA
mA
mA
mA
mA

mV
mV
%
mV
ON OFF
ON OFF
ON OFF
ON OFF
mV
mV
mA
mA
mA
mA
mA
C
rpm

mV
mV
mA
mA
mA
mA
mA
C
r/min
MPa
mV
MPa
mV
mA
mA
km/h
W
mV
mA
r/min

kg/cm2
mV
kg/cm2
mV
mA
mA
km/h
W
mV
mA
rpm
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF
ON OFF

Component
Imperial in charge
mV
mV
mV
mA
mA
mA
mA
mA

mV
mV
%
mV

mV
mV
mA
mA
mA
mA
mA
F
rpm
psi
mV
psi
mV
mA
mA
MPH
W
mV
mA
rpm

Remarks

P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T
P/T

30-97
30-107

Electrical system
Special functions of machine monitor (EMMS)

Code
No.

40909

70700
70701
60200
60300
31200
43001
40910

70300

90802

31634
10007

40982

01501

40981

40983
37501
42610
42611
42612
42613
42801
20300
99003
20227
20402

30-98

Monitoring item (displayed on screen)


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

Unit (Default: SI)


SI

Metric

Imperial

ON OFF
ON OFF
ON OFF
ON OFF
MPa
mV
mV
r/min
r/min
MPa

mA
r/min

kg/cm2
mV
mV
rpm
rpm
kg/cm2
ON OFF
ON OFF
ON OFF

psi
mV
mV
rpm
rpm
psi

W/E

ON OFF

W/E

ON OFF

W/E

ON OFF

W/E

ON OFF

W/E

mA
rpm

mA
rpm

C
C
C
V
V
kPa

mA

W/E
W/E

W/E

mA

W/E

ON OFF

W/E

ON OFF

W/E

C
C
C
V
V
kg/cm2

Remarks

P/T
P/T
P/T
P/T
W/E
W/E
P/T
P/T
P/T
VHMS
P/T
W/E
W/E

ON OFF

ON OFF

mA

Component
in charge

F
F
F
V
V
psi

VHMS
VHMS
VHMS
VHMS
VHMS
VHMS
VHMS

ON OFF

VHMS

MON
MON

D375A-6
(06)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Code
No.
20228
20242
20404
20243
20244
20405
20245
04200
04300
04401
04402
18900
37200
00201
20216
20217
20400
01002
36700
31701
31703
17500
36400
36401
36200
36300
04107
04105
37400
37401

Monitoring item (displayed on screen)


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

Unit (Default: SI)


SI

V
V
C
V
C
Mpa

r/min
%
%
mV
MPa
V
MPa
CA
C
V
Mpa
V

Metric

V
V
C
V
C
kg/cm2

rpm
%
%
mV

kg/cm2
V
kg/cm2
CA
C
V
kg/cm2
V

Imperial

V
V
F
V
F
psi

rpm
%
%
mV
psi
V
psi
CA
F
V
psi
V

Component
in charge
MON
P/T
P/T
P/T
W/E
W/E
W/E
MON
MON
MON
MON
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG

36500 Charge Pressure-Abs

Mpa

kg/cm2

psi

ENG

36501
03203
37300
31706
18500
18501
18600
17201
18700
37201
14200
14201
42700
42701
17903
18001
18100
18101

V
V
l/h
%
C
V
mg/st
CA
Nm
V
C
V
C
mV
Mpa
mV
mm
mV

V
V
l/h
%
C
V
mg/st
CA
kgm
V
C
V
C
mV

V
V
gal/h
%
F
V
mg/st
CA
lbft
V
F
V
F
mV
psi
mV
mm
mV

ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG
ENG

Charge Press Sens Volt


Battery Power Supply
Fuel Rate
Final Throttle Position
Charge Temperature
Charge Temp Sens Volt
Inject Fueling Command
PCV Close Timing
Engine Output Torque
Eng Oil Press Sens Volt
Fuel Temperature
Fuel Temp Sens Volt
ENG Oil Temperature
ENG Oil Temp. sensor
EGR Inlet Pressure-A
EGR In Press Sens Volt
EGR Valve Position
EGR Valve Pos Sens Volt

D375A-6
(03)

kg/cm2
mV
mm
mV

Remarks

Indicated in absolute pressure


(including ambient pressure)

30-99
30-109

Electrical system
Special functions of machine monitor (EMMS)

Code
No.

Monitoring item (displayed on screen)

18200 BPS Valve Position


18201 BPS Valve Pos Sens Volt
Acc
40912 P/T SW Input 1
R-sig
C-sig

Unit (Default: SI)


SI

Metric

Imperial

mm
mV

mm
mV
ON OFF
ON OFF
ON OFF

mm
mV

Component
in charge
ENG
ENG
P/T
P/T
P/T

Remarks
Not applicable for
this machine

a Entry order of monitoring items in table


The monitoring items are entered in the order of display on the "Monitoring" screen for item selection.
a Unit
The display unit can be set to SI, Metric, or Imperial unit freely (use "Unit" menu of "Default" in the
service menu to select the unit.).
"CA" in the display unit is an abbreviation for crankshaft angle.
"mg/st" in the display unit is an abbreviation for milligram/stroke.
a Component in charge
MON: The machine monitor is in charge of detection of the monitoring information.
ENG: The engine controller is in charge of detection of the monitoring information.
P/T: The power train controller is in charge of detection of the monitoring information.
W/E: The work equipment controller is in charge of detection of the monitoring information.
VHMS: The VHMS controller is in charge of detection of the monitoring Information.

30-99-1

D375A-6
(06)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

D375A-6
(03)

30-99-2
30-111

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

"Abnormality Record" (Mechanical system "Abnormality Record")

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

2. Selecting sub menu


After the "Abnormality Record" screen is
displayed, select "01 Mechanical Systems" with
the function switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the numeral input switches to select the record of that
code and confirm it with [F6].

3. Information displayed on "Abnormality Record"


screen
On the "Mechanical Systems" screen, the
following information is displayed.
(a): Sequential order from latest occurrence/Total number of records
(b): Failure code
(c): Contents of trouble
(d): Occurrence number
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if displayed)
q [F2]: Move to previous page (screen) (if displayed)
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded, "No
Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first occurrence), the service meter reading at the
first occurrence and that at the last occurrence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or resetting
of it has not been confirmed.
a For all the failure codes that the machine
monitor can record, see Troubleshooting,
"Failure codes table".

4. Deleting "Abnormality Record"


The contents of the mechanical system "Abnormality Record" cannot be deleted.

30-100

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

"Abnormality Record" (Electrical system "Abnormality Record")

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

2. Selecting sub menu


After the "Abnormality Record" screen is
displayed, select "02 Electrical Systems" with
the function switches or numeral input switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the numeral input switches to select the record of that
code and confirm it with [F6].

3. Information displayed on "Abnormality Record"


screen
On the "Electrical Systems" screen, the following
information is displayed.
(a): Sequential order from latest occurrence/Total number of records
(b): Failure code
(c): Contents of trouble
(d): Occurrence number
(e): Service meter reading at first occurrence
(f): Service meter reach at last occurrence
q [F1]: Move to next page (screen) (if displayed)
q [F2]: Move to previous page (screen) (if displayed)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to "Abnormality Record" screen
a If no "Abnormality Record" is recorded, "No
Abnormality Record" is displayed.
a If the number of occurrence time is 1 (first occurrence), the service meter reading at the
first occurrence and that at the last occurrence are the same.
a If [E] is displayed on the left of a failure code,
the abnormality is still occurring or resetting
of it has not been confirmed.
a For all the failure codes that the machine
monitor can record, see Troubleshooting,
"Failure codes table".

4. Deleting "Abnormality Record"


1) While the "Electrical Systems" screen is
displayed, perform the following operation
with the numeral input switches.
q Operation of switches (While pressing [4],
perform the operation in order):
[4]+[1]o[2]o[3]
a Operate the switches similarly to the procedure for changing the ordinary display
to the service mode.

D375A-6
(01)

30-101

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

2) Check that the screen is set in the reset


mode, and then reset the items one by one or
together with the function switches.
a If the screen is set in the reset mode,
[CLEAR] graphic mark is indicated at
[F2].
q [F2]: Delete all items
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to "Abnormality Record"
screen
q [F6]: Delete selected item
a To delete items one by one: Select the
item to be deleted with [F3] or [F4] and
press [F6].
a To delete all items together: Press [F2],
and all the items are deleted, regardless
of selection of the items.
a If [E] is displayed on the left of a failure
code, the deleting operation is accepted
but the information is not deleted.

4) If the screen to notify completion of reset is


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

3) After the "Electrical Sys. Error Reset" screen


is displayed, operate the function switches.
q [F5]: Return to "Electrical Sys. Error Reset" screen (Delete mode)
q [F6]: Execute deletion
a The following figure shows the screen
displayed when the items are reset one
by one (which is a little different from the
screen displayed when all the items are
reset together).
30-102

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Maintenance Record

The machine monitor records the maintenance information of the filters, oils, etc., which the operator
can display and check by the following operations.
When maintenance is carried out, if the data are reset in the operator mode, the number of the times of
maintenance is recorded in this section.
1. Selecting menu
Select "03 Maintenance Record" on the "Service
Menu" screen.

a The following items can be selected in the


maintenance record.
01 Engine Oil Change
02 Engine Oil Filter Change
03 Fuel Main Filter Change
41 Fuel Pre Filter Change
04 Hyd Oil Filter Change
06 Corrosion Resistor Change
07 Damper case service
08 Replacement interval of final drive case oil
10 Hydraulic oil change
19 Replacement of power train oil
20 Replacement of power train oil filter

2. Selecting maintenance record item


After the "Maintenance Record" screen is
displayed, select an item to be checked with the
function switches or numeral input switches.
q [F1]: Go to next page (screen)
q [F2]: Go to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
a You may enter a 2-digit code with the numeral input switches to select the item of that
code.

D375A-6
(03)

3. Items displayed on Maintenance Record screen.


The following items are displayed.
(a): Maintenance items
(b): Number of times of change up to now
(c): Service meter reading (SMR) at previous
change

30-103
30-115

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Maintenance Mode Change

The operating condition for maintenance function in the operation mode can be set and
changed with this menu.
q Set function effective or ineffective
q Change set replacement interval (by items)
q Initialize all set change intervals

00 Maintenance Mode On/Off


01 Engine Oil Change Int
02 Eng Oil Filter Change Int
03 Fuel Main Filter Change Int
41 Fuel Pre Filter Change Int

1. Selecting menu
Select "04 Maintenance Mode Change" on the
Service menu screen.

04 Hyd Oil Filter Change Int


07 Check and replacement interval of damper
case oil
08 Replacement interval of final drive case oil
10 Replacement interval of hydraulic oil
19 Replacement interval of power train oil
20 Replacement interval of power train oil filter
99 Use Default Value

2. Selecting sub menu


After the "Maintenance Mode Change" screen is
displayed, select an item to change the setting
with the function switches or numeral input
switches.
q [F1]: Go to next page (screen)
q [F2]: Go to previous page (screen)
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a You may enter a 2-digit code with the numeral input switches to select the record of that
code and confirm it with [F6].

a The following items can be selected on the


Change of maintenance mode screen.

30-104

3. Contents of setting of ON/OFF of maintenance


mode
After selecting "00 Maintenance Mode On/Off", if
the screen is displayed, set ON or OFF with the
function switches.
q ON: Functions of all maintenance items are
set effective in operator mode
q OFF: Functions of all maintenance items are
set ineffective in operator mode
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to Maintenance mode screen
q [F6]: Confirm selection and return to Maintenance mode screen
a Even if ON/OFF of each item has been set, if
the above setting is changed, it is applied.

4. Contents of setting of each maintenance item


After selecting each maintenance item, if the
screen is displayed, set the item with the function
switches.

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Default: Maintenance interval set in machine


monitor (Recommended by manufacturer
and not changeable).
q Set: Maintenance interval which can be set
freely. Maintenance functions in operator
mode operate on basis of this set time (which
is increased or decreased by 25 hours).
q ON: Maintenance function of this item is set
effective in operator mode.
q OFF: Maintenance function of this item is set
ineffective in operator mode.
q [F3]: Select Reduce set value (Upper) or OFF
(Lower).
q [F4]: Select Increase set value (Upper) or ON
(Lower).
q [F5]: Cancel setting before confirmation and
return to Maintenance Mode Change screen.
q [F6]: Confirm setting of upper or lower line.
a After the setting of the upper and lower lines
is confirmed with [F6] and the screen changes to the Maintenance mode change screen
with [F5], the setting is effective.
q

a If this operation is executed, the set values of


all the maintenance items are set to default
values.
q [F5]: Return to Maintenance Mode Change
screen
q [F6]: Execute default setting
a A while after [F6] is pressed, the initialization
completion screen is displayed. Then, if the
"Maintenance Mode Change" screen is displayed, initialization is completed.

Phone Number Entry

The telephone No. displayed when the user


code/failure code is displayed in the operator mode
can be input and changed according to the following
procedure.
If a telephone No. is not input with this function, no
telephone No. is displayed in the operator mode.
1. Selecting menu
Select "05 Phone Number Entry" on the "Service
Menu" screen.
5. Function of All Default Value
After selecting "99 Use Default Value", if the
screen is displayed, set with the function
switches.

D375A-6
(01)

30-105

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

2. Registering and changing telephone No.


After the "Phone Number Entry" screen is
displayed, register or change the telephone No.
q [F2]: Delete all input No.
q [F3]: Move to left position (if not blank)
q [F4]: Move to right position (if not blank)
q [F5]: Delete input digit/Return to service
menu
q [F6]: Confirm input

a Up to 14 digits can be input from the left. Input nothing in the surplus positions.
a If one of the input digits is wrong, move to
that digit (and its background changes to orange) and overwrite it with the correct digit.
a If [F6] is pressed without inputting a digit,
there is not information of phone No. Accordingly, no phone No. is displayed in the operator mode.

30-106

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Default setting (Key-on Mode)

Check and change various settings related to the


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

Default Value (ALL OFF): Default setting of


all mode items (Power: P, other 3 items:
OFF) is displayed when starting switch is
turned ON
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to the "Default" screen
q [F6]: Confirm selection and return to default
screen
a When the machine is delivered, Mode at Previous key-off.
q

2. Selecting sub menu


After the "Default" screen is displayed, select "01
Key-on Mode" with the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.
a This function sets the following 4 mode items
(which are the items set with the customize
switch in the operator mode).
q Power: P/E
q Reverse slow mode: ON/OFF
q Work equipment fine control: ON/OF
q Blade slow down: ON/OFF

3. Selecting mode
After the "Key-on Mode" screen is displayed,
select the mode to be set with the function
switches.
q Mode at previous key-OFF: Final mode in
previous operation is displayed when starting
switch is turned ON
D375A-6
(01)

30-107

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Default setting (Setting of unit)

Check and change various settings related to the


machine monitor and the machine with the "Default".
The unit selecting function is used to select the unit
of the data displayed for monitoring, etc.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.

2. Selecting sub menu


After the "Default" screen is displayed, select "02
Unit" with the function switches or numeral input
switches.
a Select this item similarly to an item on the
"Service Menu" screen.

3. Selecting unit
After the "Unit" screen is displayed, select the
unit to be set with the function switches.
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to the "Default" screen
q [F6]: Confirm selection and return to default
screen
a When the machine is delivered, the SI unit
system is set.

30-108

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Default setting (Setting of maintenance password)

Check and change various settings related to the


machine monitor and the machine with the "Default".
The function of setting maintenance password is
used to set the display of the password screen when
the functions related to the maintenance are used in
the operator mode.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.
4. Displaying maintenance password screen
When the following operation is performed, the
password screen is displayed in the operator
mode.
q The ordinary screen is changed to the maintenance mode (with [F5]) and then the "Maintenance table" screen is changed to the
"Maintenance interval reset" screen.

2. Selecting sub menu


After the "Default" screen is displayed, select "03
Maintenance Password" with the function
switches or numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

5. Changing maintenance password


The password can be changed by operating the
switches specially in the operator mode.
a See "Function of changing maintenance
password" in the operator mode.
a Default password: [000000]
a If the password setting is changed from "Enable" to "Disable", the password is reset to
the default.
a When "Enable" is set again, be sure to set a
new password.
a The maintenance password is different from
the engine start lock password.

3. Selecting Enable/Disable
After the Maintenance Password screen is
displayed, select the setting with the function
switches.
q Disable: Password screen is not displayed
q Enable: Password screen is displayed
q [F3]: Move to lower item
q [F4]: Move to upper item
q [F5]: Cancel selection and return to the "Default" screen
q [F6]: Confirm selection and return to default
screen

D375A-6
(01)

30-109

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Default setting (Setting of camera)

Check and change various settings related to the


machine monitor and the machine with the "Default".
The camera setting function is used to set default
setting and removal of a camera.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.

a After "Camera" screen is displayed, camera


1 can be always set.
When 2 or more cameras are connected, if
camera 1 is set, the screen changes to
setting of camera 2 automatically.
a After confirming the setting of each line with
[F6], return to the "Default" screen with [F5],
and the setting is effective.
a If a camera is connected but not set normally
with this function, the graphic mark of camera
is not displayed at [F3] in the operator mode.
Accordingly, the image of the camera cannot
be used.
a If 2 or more cameras are connected, be sure
to set the use of them from camera 1 in order.
a The function of displaying 2 images simultaneously is effective when use of camera 1
and camera 2 is set.
a When a camera is installed, check that the
displayed image is not inverted horizontally
in the operator mode.

2. Selecting sub menu


After the "Default" screen is displayed, select "04
Camera" with the function switches or numeral
input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

3. Selecting camera setting


After the "Camera" setting screen is displayed,
select the setting with the function switches.
q OFF: Camera is not connected
q Original image: Image of connected camera
is displayed in original position
(as in mirror, used as back monitor)
q Reverse image: Image of connected camera
is displayed in reverse position (as seen directly, used as front or side monitor)
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel setting before confirmation and
return to Default screen
q [F6]: Confirm selection in each line
30-110

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Default setting (Setting of ECO display)

Check and change various settings related to the


machine monitor and the machine with the "Default".
The ECO display setting function is used to set the
display of the ECO gauge.
1. Selecting menu
Select "06 Default" on the "Service Menu"
screen.

a Display of ECO gauge (a)

2. Selecting sub menu


After the "Default" screen is displayed, select "05
ECO Display" with the function switches or
numeral input switches.
a Select this item similarly to an item on the
"Service Menu" screen.

3. Selecting display setting


After the "ECO Display" screen is displayed,
select the setting with the function switches.
q ON: Display ECO
q OFF: Do not display ECO
q [F3]: Move to left item
q [F4]: Move to right item
q [F5]: Cancel selection and return to the "Default" screen
q [F6]: Confirm selection and return to default
screen
a If ECO display is turned ON, ECO is displayed when the screen changes to the ordinary screen.

D375A-6
(01)

30-111

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjusting

The operator can adjust various items related to the


machine with the machine monitor.
When using an adjustment item, select it according
to the following procedure.
1. Selecting menu
Select "07 Adjustment" in the "Service menu"
screen.

2. Selecting adjustment items


After the "Adjustment" screen is displayed, input
the 4-digit adjustment ID of the adjustment item
to be used with the numeral input switches.
q [F5]: Cancel adjustment and return to Service menu screen
q [F6]: Confirm input adjustment ID and go to
Adjustment screen
a For the adjustment ID's and their adjustment
items, see the adjustment items table.

3. Displaying adjustment screen


After the "Adjustment" screen for the adjustment
ID is displayed, you can start adjustment.
a In the figure, adjustment ID [0002] is selected
and displayed as an example.
a "000", "00", and "0" on the left of the adjustment ID must be filled but they are not displayed on the adjustment screen.
a The functions given to function switches [F3]
[F6] depend on the adjustment item.
a For the method of operating each adjustment
item, see the explanation of its adjustment
ID.

a lf the input adjustment ID is incorrect, the


message of "Not Available" is displayed and
the ID input screen does not change (another
ID can be input again with the numeral input
switches while this screen is displayed).

30-112

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment items table


Adjustment
ID
0002
0004
0005
0007
0009
0010
0031
0036
0041

Adjustment item
Power train controller initialization
Work equipment specification setting
Brake pedal potentiometer initial correction
Engine decelerator cutting
Pitch angle sensor initial correction
Fan 70% mode
Work equipment controller initialization
Shoe slip control specification code setting
Travel lever code setting

0530

Stall mode

1005
1012
1013
1014
1015
1016
2021
2022
5535
5537
5538
6001
6002
6003
7842
7843
7845
7847

Fan 100 % mode


Steering lever neutral position adjustment
Steering lever leftmost position adjustment
Steering lever rightmost position adjustment
Right brake oil pressure offset
Left brake oil pressure offset
Power train controller voltage check mode
Work equipment controller voltage check mode
Both steering clutch disengage mode
Left steering clutch oil pressure offset
Right steering clutch oil pressure offset
R1 reverse slow set speed
R2 reverse slow set speed
R3 reverse slow set speed
Transmission clutch IP and fill time automatic initial correction
Transmission clutch IP manual initial correction
Transmission clutch IP learning display
Transmission clutch fill time manual initial correction

9995

Control brake release mode

9996
9997
9998

Sudden stop prevent valve operation mode


High idle cut mode
Max. gear speed setting mode

D375A-6
(03)

Remarks

Resetting auto-decelerating function

Setting and resetting uni-direction lever


Recommended mode of torque converter stall

Fine adjustment of reverse slow mode


Fine adjustment of reverse slow mode
Fine adjustment of reverse slow mode

Control brake: Brake ECMV (Right and


left)

30-113
30-125

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 0002 (Power train controller


initialization)

Adjustment ID: 0004 (Work equipment specification setting)

This adjustment code is used to initialize the


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

Functions of function switches


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

Functions of function switches


[F3]: Increase specification value [CODE]
[F4]: Decrease specification value [CODE]
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save setting

Operating method:
1] Press [F6] and check that the alarm
buzzer sounds.
2] Check that the displayed specification
code [CODE] has changed from [1x1] to
[111].
a If specification code [111] is not displayed, the controller unit may be defective.
a Even if this adjustment code is turned off,
the setting is effective.

Operating method:
1] Press [F3] or [F4] to select the specification value [CODE] of the work equipment
concerned.

30-114

This adjustment code is used to make the


work equipment controller recognize the type
of the work equipment.
a After the work equipment controller or the
work equipment is replaced, be sure to carry
out this adjustment once.

CODE
Type of work equipment
0
Dual tiltdozer
1
Single tiltdozer

2] Press [F6] and check that the alarm


buzzer sounds.
k If the specification of the work equipment
is different from the setting in the controller, the work equipment may move unexpectedly or an error may be made.
Accordingly, be sure to match the controller to the work equipment.
a Even if this adjustment code is turned off, the
setting is effective.

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 0005 (Brake pedal potentiometer


initial correction)

Adjustment ID: 0007 (Engine decelerator cutting)

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

This adjustment code is used to make the


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

Functions of function switches


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

Functions of function switches


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

Operating method:
1] Check that the brake pedal is in the
neutral position (it is not pressed at all)
and keep it in that position.
2] Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the correction is effective.
a This adjustment code is used to make the
controller recognize the zero point of the
potentiometer. It is not used to adjust the
braking force.

Operating method:
When this adjustment code is displayed, its
function is effective and the auto-deceleration function is stopped.
a After this adjustment code is turned OFF,
its function is ineffective.

D375A-6
(01)

30-115

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 0009 (Pitch angle sensor initial


correction)

Adjustment ID: 0010 (Fan 70% mode)

This adjustment code is used to forcibly set


the cooling fan speed to about 70%.
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

This adjustment code is used to make the


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

Functions of function switches


[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save corrected value
Operating method:
1] Check that the machine is level.
2] Press [F6] and check that the alarm
buzzer sounds.
a If the adjustment is performed, displayed
item [BODY PITCH ANGLE] changes to
[0.0] (No other displayed item changes).
a Even if this adjustment code is turned off,
the correction is effective.

30-116

Functions of function switches


[F3]: Increase adjustment value [FAN 70 %
SPEED MODE]
[F4]: Decrease adjustment value [FAN 70 %
SPEED MODE]
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Unused

Operating method:
The function is effective at the time when this
adjustment is displayed and the cooling fan
speed is controlled to about 70% of the
maximum speed.
a After this adjustment code is turned OFF,
its function is ineffective.

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 0031 (Work equipment controller


initialization)

Adjustment ID: 0036 (Shoe slip control specification code setting)

This adjustment code is used to initialize the


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

Functions of function switches


[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save setting
Operating method:
1] Press [F6] and check that the alarm
buzzer sounds.
2] Check that the displayed specification
code [CODE] has changed from [2x2] to
[222].
a If specification code [222] is not displayed, the controller wiring harness or
the controller unit may be defective.
a Even if this adjustment code is turned off,
the setting is effective.

D375A-6
(01)

This adjustment code is used to change the


rocky terrain specification setting when the
shoe slip control is used.

a When the shoe slip control operates, if shoe


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

Functions of function switches


[F3]: Return
[F4]: Go
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Confirm selection

Operating method:
1] Change the setting from [SSC SPEC H]
to [SSC SPEC L] by pressing [F3] or [F4].
2] Press [F6] to define the selection.
a At this time, check that alarm buzzer
sounds.
a Even if this adjustment code is turned off,
the setting is effective.

30-117

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 0041 (Travel lever code setting)

This adjustment code is used to correct the


set value of the travel lever code recognized
by the power train controller when it is different from the lever that is actually installed.
a If the power train controller is replaced while
a non-standard travel lever (for example, a
uni-direction lever) is installed, be sure to
perform this adjustment once.
q Functions of function switches
[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save setting
q

Operating method:
1] Perform adjustment ID "0002" (Initialization of power train controller) and "0031"
(Initialization of work equipment
controller).
a After the above operation has been
carried out, an error is displayed.
2] Enter adjustment ID "0041".
3] Press [F6] and check that the alarm
buzzer sounds.
4] Check that the displayed specification
code [CODE] has changed from [1x1] to
[111].
a If specification code [111] is not displayed, the controller unit may be defective.
a Even if this adjustment code is turned
off, the setting is effective.

30-130
30-117-1

D375A-6
(03)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

D375A-6
(03)

30-117-2
30-131

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 0530 (Stall mode)

Adjustment ID: 1005 (Fan 100% mode)

This adjustment code is used to set the fan


speed in the 100% mode automatically and
make it possible to set the preset (gear speed
at start) to [F3-R3] to stall the torque converter.
a The preset (gear speed at start) can be set to
[F3-R3] only while this adjustment code is selected.
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q Functions of function switches
[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Unused

Mode setting information within screen


[P-AUTO SFT MODE]: Automatic Gearshift
In P Mode
[E-AUTO SFT MODE]: Automatic Gearshift
In E Mode
[P-MANUAL SFT MODE]: Manual Gearshift
In P Mode
[E-MANUAL SFT MODE]: Manual Gearshift
In E Mode
a When using this adjustment code, be sure to
select "P-MANUAL SFT MODE".
q Operating method:
when this adjustment code is displayed, its
function is effective and the preset (gear
speed at start) is set to [F3-R3].
k This adjustment code does not stall the
torque converter automatically. Accordingly, operate the levers and pedals securely when stalling the torque converter
(For the procedure for stalling the torque
converter, see Measuring engine speed).
a When using this adjustment code, be sure to
keep the hydraulic oil temperature above 45
C.(If the hydraulic oil temperature drops
below 40C, the fan speed fluctuates)
a After this adjustment code is turned OFF, its
function is ineffective.
q

30-132
30-118

This adjustment code is used to set the cooling fan speed to about 100% forcibly.
It is also used to set the adjustment value of
the maximum speed.
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
a Functions of function switches
[F3]: Increase adjustment value [FAN 100 %
SPEED MODE]
[F4]: Decrease adjustment value [FAN 100 %
SPEED MODE]
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value

Operating method:
a When this adjustment code is displayed,
its function is effective and the cooling fan
speed is controlled to about 100% of the
maximum speed.
1] increase Or decrease the adjustment
value by pressing [F3] or [F4].
2] when confirming the adjustment value,
press [F6] and check that the alarm
buzzer sounds.
a When using this adjustment code, be
sure to keep the hydraulic oil temperature
above 45C.(If the hydraulic oil temperature drops below 40C, the fan speed
fluctuates)
a After this adjustment code is turned OFF,
its function is ineffective but the set adjustment value is effective.

D375A-6
(03)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 1012 (Steering lever neutral position adjustment)

Adjustment ID: 1013 (Steering lever leftmost


position adjustment)

This adjustment code is used to make the


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

Functions of function switches


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

Functions of function switches


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

Operating method:
1] Check that the PCCS lever is in the
neutral position of the steering direction
and keep it in that position.
2] Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the neutral position
of the potentiometer. It is not used to adjust the steering force.

Operating method:
1] Operate the PCCS lever in the steering
direction to the left stroke end and keep it
there.
2] Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the leftmost position
of the potentiometer. It is not used to adjust the steering force.

D375A-6
(01)

This adjustment code is used to make the


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

30-119

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 1014 (Steering lever rightmost


position adjustment)

Adjustment ID: 1015 (Right brake oil pressure


offset)

This adjustment code is used to make the


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

Functions of function switches


[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value
Operating method:
1] Operate the PCCS lever in the steering
direction to the right stroke end and keep
it there.
2] Press [F6] and check that the alarm
buzzer sounds.
a Even if the adjustment is carried out, the
displayed value does not change.
a Even if this adjustment code is turned off,
the adjustment is effective.
a This adjustment code is used to make the
controller recognize the rightmost position of the potentiometer. It is not used to
adjust the steering force.

30-134
30-120

This adjustment code is used to adjust the


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

Functions of function switches


[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value

Information displayed on screen


The offset oil pressure is displayed and the
adjustment value is increased or decreased
by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0
kg/cm2}.
a The adjustment range is -0.294 - 0.294
MPa {-3 - 3 kg/cm2}.

Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a If an adjustment has been performed, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.
a It is not necessary to operate the brake
during adjustment. After finishing adjustment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
a Even if this adjustment code is turned off,
the adjustment is effective.

D375A-6
(03)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 1016 (Left brake oil pressure


offset)

Adjustment ID: 2021 (Power train controller


voltage check mode)

This adjustment code is used to adjust the


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

Functions of function switches


[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value
Information displayed on screen
The offset oil pressure is displayed and the
adjustment value is increased or decreased
by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0
kg/cm2}.
a The adjustment range is -0.294 0.294
MPa {-3 3 kg/cm2}.
Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a It is not necessary to operate the brake
during adjustment. After finishing adjustment, however, operate the brake and
check that there is not a problem in the
actual brake performance.
a If an adjustment has been performed, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.
a Even if this adjustment code is turned off,
the adjustment is effective.

D375A-6
(03)

This adjustment code is used to check the


constant power supply voltage and switch
power supply voltage applied to the power
train controller.
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

Functions of function switches


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

Information displayed on screen


[PT CONTROLLER UNSWITCH POWER]:
Constant power supply voltage
[PT CONTROLLER ACC POWER]: Switch
power supply voltage

Operating method:
When this adjustment code is displayed, its
function is effective and the constant power
supply voltage and switch power supply
voltage are displayed simultaneously.
a After this adjustment code is turned OFF,
its function is ineffective.

30-121
30-135

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 2022 (Work equipment controller


voltage check mode)

Adjustment ID: 5535 (Both steering clutch disengage mode)

This adjustment code is used to check the


constant power supply voltage and switch
power supply voltage applied to the work
equipment controller.
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

Functions of function switches


[F3]: Unused
[F4]: Unused
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Unused
Information displayed on screen
[WE CONTROLLER UNSWITCH POWER]:
Constant power supply voltage
[WE CONTROLLER ACC POWER]: Switch
power supply voltage
Operating method:
When this adjustment code is displayed, its
function is effective and the constant power
supply voltage and switch power supply
voltage are displayed simultaneously.
a After this adjustment code is turned OFF,
its function is ineffective.

30-122

This adjustment code is used to disengage


both steering clutches with the parking brake
ON.

a Used to check the torque converter lockup


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

Functions of function switches


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

Operating method:
When this adjustment code is displayed, its
function is effective and both steering
clutches are disengaged.
a After this adjustment code is turned OFF,
its function is ineffective.

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 5537 (Left steering clutch oil pressure offset)

a It is not necessary to steer the machine


during adjustment. After finishing adjustment, however, steer the machine and
check that there is no problem in the actual steering performance.
a Even if this adjustment code is turned off,
the adjustment is effective.

This adjustment code is used to manually adjust the pressure of the left steering clutch.
q If a machine has been operated for a long period of time, the clutch oil pressure may be
out of the standard pressure range because
of wear of the clutch disc and the machine
may not make a smooth gradual turn.
In this case, this adjustment is effective to
adjustment of oil pressure for smooth gradual
turn.
a Use this adjustment code for work when necessary.
q

Functions of function switches


[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selection
screen (ID inputting screen)
[F6]: Save adjustment value

Information displayed on screen


The offset oil pressure is displayed and the
adjustment value is increased or decreased
by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0
kg/cm2}.
a The adjustment range is -0.294 0.294
MPa {-3 3 kg/cm2}.

Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a If an adjustment has been performed, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.

D375A-6
(03)

30-123
30-137

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 5538 (Right steering clutch oil


pressure offset)

a It is not necessary to steer the machine


during adjustment. After finishing adjustment, however, steer the machine and
check that there is no problem in the actual steering performance.
a Even if this adjustment code is turned off,
the adjustment is effective.

This adjustment code is used to manually adjust the pressure of the left steering clutch.
q If a machine has been operated for a long period of time, the clutch oil pressure may be
out of the standard pressure range because
of wear of the clutch disc and the machine
may not make a smooth gradual turn.
In this case, this adjustment is effective to
adjustment of oil pressure for smooth gradual
turn.
a Use this adjustment code for work when necessary.
q

Functions of function switches


[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selection
screen (ID inputting screen)
[F6]: Save adjustment value

Information displayed on screen


The offset oil pressure is displayed and the
adjustment value is increased or decreased
by 0.0098 MPa {0.1 kg/cm2} (The value
displayed on the screen is multiplied by 100).
a The default adjustment value is 0 MPa {0
kg/cm2}.
a The adjustment range is -0.294 0.294
MPa {-3 3 kg/cm2}.

Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a If an adjustment has been performed, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.

30-138
30-124

D375A-6
(03)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 6001 (R1 reverse slow set speed)

Adjustment ID: 6002 (R2 reverse slow set speed)

This adjustment code is used to adjust the


engine speed applied to travel at gear speed
R1 with the reverse slow mode ON.
a Use this adjustment code for work when necessary.

Functions of function switches


[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value

Functions of function switches


[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value

Information displayed on screen


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

Information displayed on screen


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

Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a If the set speed has been adjusted, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment, however, drive the machine at R1
with the reverse slow mode ON and
check that there is not a problem in the
actual travel speed.
a Even if this adjustment code is turned off,
the adjustment is effective.

Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a If the set speed has been adjusted, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment, however, drive the machine at R2
with the reverse slow mode ON and
check that there is not a problem in the
actual travel speed.
a Even if this adjustment code is turned off,
the adjustment is effective.

D375A-6
(01)

This adjustment code is used to adjust the


engine speed applied to travel at gear speed
R2 with the reverse slow mode ON.
a Use this adjustment code for work when necessary.

30-125

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 6003 (R3 reverse slow set


speed)

Adjustment ID: 7842 (Transmission clutch IP and


fill time automatic initial correction)

This adjustment code is used to adjust the


engine speed applied to travel at gear speed
R3 with the reverse slow mode ON.
a Use this adjustment code for work when necessary.

Functions of function switches


[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value
Information displayed on screen
The lower speed (reduced from the high idle
speed of 1,900 rpm) is displayed and the
adjustment value is increased or decreased
in 50 rpm units.
a The adjustment value at shipment is 300
rpm (Display: 30).
(Setting at shipment: 1,900 - 300 = 1,600
rpm)
Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a If the set speed has been adjusted, the
adjustment value is displayed. It can be
adjusted again within the allowable
range.
a It is not necessary to drive the machine
during adjustment. After finishing adjustment, however, drive the machine at R2
with the reverse slow mode ON and
check that there is not a problem in the
actual travel speed.
a Even if this adjustment code is turned off,
the adjustment is effective.

30-126

This adjustment code is used to make the


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

Functions of function switches


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

Conditions for correction work


1] [ENGINE SPEED]: 1,700 1,950 rpm
2] [T/C TEMPERATURE]: 65 85C
3] Parking brake lever: LOCK position
4] PCCS lever: Neutral position
a When using this adjustment code, keep
the above conditions (In particular, increase the power train oil temperature
sufficiently before starting adjustment).

Operating method:
1] Stall the torque converter so that the
torque converter oil temperature will be
stabilized in the range of 65 85C.
2] Fix the engine speed in the range of 1,700
1,900 rpm.
3] Set the PCCS lever in the neutral position
and set the parking brake lever in the lock
position.
4] Input adjustment ID [7842] directly with
the numeral input switches and press
[F6].
5] Press [F6] again.
a IP correction is started automatically.
a Which clutch is being adjusted is displayed in section "a".

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

6] If [End of teaching. Press F6] is displayed


in section "a", press [F6] again.
a The buzzer sounds and the adjustment value is saved.
a This work takes 3 - 5 minutes to complete.

Adjustment ID: 7843 (Transmission clutch IP


manual initial correction)

This adjustment code is used to carry out correction manually when the correction is not
carried out normally by the operation of IP
automatic correction (Adjustment ID: 7842.
a Use this adjustment code after the IP correction work, if necessary.

D375A-6
(01)

Functions of function switches


[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value
a If [F2] is pressed while [F1] is pressed, all
the correction values are set to 0.

Functions of shift up/down switches


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

Conditions for correction work


Same as the conditions for IP automatic
correction (Adjustment ID: 7842).

Operating method:
1] Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2] Select a clutch to be corrected manually
with the shift-up or shift-down switches.
3] Increase or decrease the adjustment
value by pressing [F3] or [F4].
4] Press [F6] and check that the alarm
buzzer sounds.
a The machine does not move during the
correction work.
a Even if this adjustment code is turned off,
the adjustment is effective.

30-127

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 7845 (Transmission clutch IP


learning display)

Adjustment ID: 7847 (Transmission clutch fill


time manual initial correction)

This adjustment code is used to check the information of correction made by the operation of IP automatic correction (Adjustment
ID: 7842) or IP manual correction (Adjustment ID: 7843).
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.
q Functions of function switches
[F3]: Change display
[F4]: Change display
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Unused

Operating method:
When this adjustment code is displayed, its
function is effective and the correction information is displayed.
a After this adjustment code is turned OFF,
its function is ineffective.

This adjustment code is used to carry out correction manually when the correction is not
carried out normally by the operation of fill
time automatic correction (Adjustment ID:
7842).
a Use this adjustment code after the fill time
correction work, if necessary.
q Functions of function switches
[F3]: Increase adjustment value
[F4]: Decrease adjustment value
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value
a If [F2] is pressed while [F1] is pressed, all the
correction values are set to 0.
q Functions of shift up/down switches
You can select a clutch to be corrected
manually with the shift-up and shift-down
switches.
a The value displayed when the clutch is selected is correction information set automatically or manually before.
q Conditions for correction work
Same as the conditions for fill time automatic
correction (Adjustment ID: 7842).
q

30-128

Operating method:
1] Start the engine and keep its speed in the
specified range of condition with the fuel
control dial.
2] Select a clutch to be corrected manually
with the shift-up or shift-down switches.
3] Increase or decrease the adjustment
value by pressing [F3] or [F4].
4] Press [F6] and check that the alarm
buzzer sounds.
a The machine does not move during the
correction work.
a Even if this adjustment code is turned off,
the adjustment is effective.

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 9995 (Control brake release


mode)

Adjustment ID: 9996 (Sudden stop prevent valve


operation mode)

This adjustment code is used to release the


control brake (right and left brake ECMV) to
check the operation of the backup brake
(brake pedal solenoid valve).
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

Functions of function switches


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

Functions of function switches


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

Operating method:
When this adjustment code is displayed, its
function is effective and the control brake
(right and left brake ECMV) is kept released.
a After this adjustment code is turned OFF,
its function is ineffective.

Operating method:
When this adjustment code is displayed, its
function is effective and the sudden stop
prevent solenoid valve and right and left
brake ECMV are kept stopped.
a After this adjustment code is turned OFF,
its function is ineffective.

D375A-6
(01)

This adjustment code is used to stop the sudden stop prevent solenoid valve and right
and left brake ECMV to check the operation
of the sudden stop prevent valve.
a Use this adjustment code for testing, adjusting, or troubleshooting when necessary.

30-129

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Adjustment ID: 9997 (High idle cut mode)

This adjustment code is used to limit the high


idle speed.
a Use this adjustment code for work when necessary.

Adjustment ID: 9998 (Max. gear speed setting


mode)

Functions of function switches


[F3]: Increase adjustment value [HI IDLE
RPM SET MODE]
[F4]: Decrease adjustment value [HI IDLE
RPM SET MODE]
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value
Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a To reset the high idle speed limit, set it to
the original high idle speed (1,900 rpm)
that was set at the time the machine was
shipped.
a The adjustment value is increased or decreased in 50 rpm units.
a Even if this adjustment code is turned off,
the setting is effective.

30-130

This adjustment code is used to limit the


maximum transmission gear speed.
q The limited gear speed is applied in both automatic gearshift mode and manual gearshift
mode.
a Use this adjustment code for work when necessary.
q

Functions of function switches


[F3]: Increase adjustment value [MAX
SHIFT]
[F4]: Decrease adjustment value [MAX
SHIFT]
[F5]: Return to adjustment item selecting
screen (ID inputting screen)
[F6]: Save adjustment value

Operating method:
1] Increase or decrease the adjustment
value by pressing [F3] or [F4].
2] Press [F6] and check that the alarm
buzzer sounds.
a When resetting the limitation of the maximum gear speed, set the adjustment value to the maximum gear speed (3RD)
which is the initial setting at shipment.
a Setting with this adjustment code becomes effective only after the starting
switch is turned to OFF position and then
to ON position again.

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

PM clinic

3rd screen

4th screen (The figure shows VHMS installation specification)

5th screen

6th screen (The figure shows VHMS installation specification)

The machine monitor can check the condition of


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

2) Information displayed on Pm Clinic screen


The Pm Clinic function displays the following
information on 6 pages.
q 1st screen

D375A-6
(01)

2nd screen (The figure shows VHMS installation specification)

30-131

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

q
q
q
q
q

[F1]: Change screen


[F2]: Change screen
[F3]: Reset holding
[F4]: Hold (displayed data)
[F5]: Return to service menu screen

3) Holding displayed information


The displayed information can be held and
released with [F3] and [F4].

30-132

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Cylinder Cut-Out operation

The operator can perform Cylinder Cut-Out


operation with the machine monitor.
Reduced cylinder mode operation means to run
the engine with 1 or more fuel injectors disabled
electrically to reduce the number of effective
cylinders. This operation is used to find out a
cylinder which does not output power normally
(combustion in it is abnormal).
1) Selecting menu
Select "09 Cylinder Cut-Out" on the "Service
Menu" screen.

2) Selecting cylinder to be disabled


After the "Cylinder Cut-Out" screen is
displayed, select a cylinder to be Cut-Out
with the function switches.
q [F1]: Move selection mark (R) to left
q Move selection mark (R) to right
q [F3]: Reset holding
q [F4]: Hold
q [F5]: Return to service menu screen
q [F6]: Confirm selection
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes white,
the cylinder is disabled.
a If the machine monitor disables a cylinder
but the engine controller cannot disable
that cylinder, the background of the cylinder No. becomes yellow.
a One or more cylinders can be disabled.

D375A-6
(01)

3) Resetting disabled cylinder


When changing a cylinder to be disabled or
when reduced cylinder mode operation is
finished, select a disabled cylinder to be
reset with the function switches.
a This operation may be performed while
the engine is running.
a When [F6] is pressed, if background (a) of
the selected cylinder No. becomes light
blue, the cylinder is reset.
a If the machine monitor rests a disabled
cylinder but the engine controller cannot
reset that disabled cylinder, the background of the cylinder No. becomes red.
a The reduced cylinder mode operation is
not automatically reset after the screen
returns to the operator mode. Accordingly, be sure to perform the resetting operation after the reduced cylinder mode
operation is finished.
4) Function of holding displayed information
If [F4] is pressed during the reduced cylinder
mode operation, the displayed information is
newly held (c) (The real-time information is
kept displayed on the left side).
a While the information is held, if [F3] is
pressed, the holding function is reset.
a The holding function is effective, regardless of setting of the reduced cylinder
mode operation.

30-133

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

[Reference]
q

If a normally operating cylinder is disabled, the following phenomena occur.


1) Lowering of engine speed
2) Increase of final injection rate
command (quantity)
If the engine is running near the high idle,
however, the engine speed may not lower
for the reason of engine control.
In this case, lower the engine speed with
the fuel control dial and judge by increase
of the injection rate command.

Display of No Injection

If the engine is operated after long storage of the


machine, it may be worn or damaged because of
insufficient lubrication with oil. To prevent this,
the function to lubricate the engine before
starting it by cranking it without injecting fuel is
installed.
Set the no-injection cranking while the engine is
stopped.
1) Selecting menu
Select "10 No Injection" on the "Service
Menu" screen.

2) Preparation for no injection cranking


When the No injection screen is displayed,
the machine monitor checks automatically if
no injection cranking can be performed.
If no injection cranking can be performed, the
screen changes to the next screen automatically.
a If no injection cranking cannot be performed because the engine is running or
the communication is abnormal, the
screen does not change from the following screen. In this case, depress [F5] to
return to the "Service Menu" screen and
solvethe problem.

30-134

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

3) Display of confirmation screen


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

4) Starting no injection cranking


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

D375A-6
(01)

5) Finishing no injection cranking


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

6) Prohibiting no injection cranking


If the operator tries to perform the no injection
cranking while the engine is running, the
message that the engine is running is
displayed and the no injection cranking is not
set effective.
a Depress [F5] to return to the "Service
Menu" screen, stop the engine, and select no injection cranking again.

30-135

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Display of Fuel Consumption

This function calculates the hourly fuel


consumption from the actual fuel consumption in
a measuring period and indicates it.
1) Selecting menu
Select "11 Fuel Consumption" on the
"Service Menu" screen.

2) Starting measurement
After the screen of "Fuel Consumption" is
displayed, start measurement with the function switches.
q [F1]: START
q [F2]: CLEAR
q [F5]: Return to service menu screen
a When the screen of "Fuel Consumption"
is displayed, if a data is indicated, it is the
data of the previous measurement. This
data is not an obstacle to new measurement and can be deleted by pressing
[F2].
a If [F1] is pressed, the data is displayed on
the starting date and time side and measurement starts.
a The display unit of the fuel changes according to the unit set with the initialization (unit setting) function.
SI and meter: l/h, inch: gal/h

30-136

3) Display and function during measurement


Clock mark (a) flashes during measurement.
a While the fuel consumption is being measured, the operator can work with the operator mode and other functions.
Measurement is not finished until this
screen is displayed again and [F1] is
pressed (Even if the starting switch is
turned OFF, this function is kept effective,
although fuel consumption is measured
only while the engine is running).

4) Finishing measurement
Press [F1], and measurement is finished and
the data are displayed on the finishing date
and time side.
5) Displaying fuel consumption
If the measurement is finished, the hourly
fuel consumption calculated from the fuel
consumption calculated by the engine
controller and the elapsed time are
displayed.

D375A-6
(01)

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

[F1]: Change screen


[F2]: Change screen
q [F5]: Return to service menu screen
2nd screen
1] F1 travel distance
The cumulative travel distance in
(theoretical value) is displayed.
2] F2 travel distance
The cumulative travel distance in
(theoretical value) is displayed
3] F3 travel distance
The cumulative travel distance in
(theoretical value) is displayed.
4] R1 travel distance
The cumulative travel distance in
(theoretical value) is displayed.
5] R2 travel distance
The cumulative travel distance in
(theoretical value) is displayed.
6] R3 travel distance
The cumulative travel distance in
(theoretical value) is displayed.

Display of saved load

This function displays the data accumulated


since the machine started operation.
(It displays the data saved in the controller.)

1) Selecting menu
Select "12 Display of saved load" on the
"Service Menu" screen.

2) Information displayed on Display of saved


load screen
The following Information is displayed 2
screens of the "Display of saved load"
screen.
q

F1

F2

F3

R1

R2

R3

1st screen
1] 1000 rpm service meter
The number of cumulative operation
hours at engine speed higher than 1,000
rpm is displayed.
2] Forward travel distance
The cumulative forward travel distance
(theoretical value) is displayed.
3] Reverse travel distance
The cumulative reverse travel distance
(theoretical value) is displayed.

D375A-6
(01)

30-137

DRAFT
Electrial system
Special functions of machine monitor (EMMS)

Setting of VHMS
This function is used to set installation of VHMS.
If VHMS is installed when shipped, this setting
has been completed.
1) Selecting menu
Select "13 Setting of VHMS" on the "Service
Menu" screen.

Snap shot (VHMS specification)


This function sends a snap shot trigger
command to the VHMS controller to execute the
snap shot.
VHMS specification has a manual snap shot
function and an auto snap shot function.
A manual snap shot can save the data for seven
minutes and 30 seconds into the VHMS
controller in order for them to be used for troubleshooting purposes.
1) Selecting menu
Select "14 Snap shot" on the "Service Menu"
screen.

2) Setting of installation of VHMS


After the "Setting of VHMS" screen is
displayed, select "ON" with the function
switch.
To reset the setting of VHMS, select "OFF".
a Perform setting securely to prevent incorrect display and partial disability of the
VHMS function.

q
q
q
q

2) Operating method of manual snap shot


After the "Snap shot" screen is displayed,
start measuring data with the function switch.
If [F1] is pressed to start measurement,
display of [START] goes off. If measurement
is finished, [START] is displayed again.
a The elapsed measurement time is indicated in minute and second, and progress is indicated with a bar graph.
a If [F5] is pressed during measurement,
the screen returns to the service menu
screen but measurement is continued.

[F3]: Select "ON"


[F4]: Select "OFF"
[F5]: Return to service menu screen
[F6]: Confirm selection

q
q

30-152
30-138

[F1]: Start measurement


[F5]: Return to service menu screen

D375A-6
(03)

DRAFT
Electrial system
Handling of voltage circuit of engine controller

Handling of voltage circuit of engine controller


1. Disconnecting or connecting operation of the
connector between the engine controller and the
engine shall be performed only when the starting
switch is in the OFF position.
k Before connecting the harness connector, be sure to completely remove sand,
dust, water, etc., from inside of controller
side connector.
2. Do not start the engine while the T adapter is
inserted or connected to the connector between
the engine controller and the engine for diagnosis.
a The allowed starting switch position is either
OFF or ON. It must not be set to START position.

D375A-6
(01)

30-139

DRAFT
Electrial system
Adjustment method when controller has been replaced

Adjustment method when controller has been replaced


a After machine is assembled or the power train
controller or the work equipment controller is replaced, adjust the system according to the following procedure.
k If the system is not adjusted, the machine
may not operate normally but may move unexpectedly. Accordingly, be sure to adjust it.
a Precautions for replacing a controller:
If a controller is replaced, the memory of the oil
and filter maintenance mode is reset. Accordingly, take a record of the next replacement
periods of the oils and filters.
a Precautions for replacing a controller:
Stop the machine in a safe place and turn the
starting switch to the OFF position.
a Since the controller performs the finishing process for about 30 seconds after the starting
switch is turned to the OFF position and the battery relay is turned OFF, do not remove the controller immediately.
1. Controller initial setting
1) Connect all the wiring harnesses and controllers.
2) Turn the starting switch to the ON position.
a The buzzer sounds and the machine
monitor indicates an error.
3) Turn the starting switch to the OFF position
and wait for approx. 30 seconds.
a It takes approx. 30 seconds to shut down
the controller completely after the battery
relay is turned OFF.
4) Turn the starting switch to the ON position
again.
a The machine monitor lights up, the buzzer sounds, and an error is indicated.
5) While pressing numeral input switch [4],
press [1], [2] and [3] in order to set the
machine monitor in the service mode.

30-140

6) Select "07 Adjustment" in the "Service


menu".

7) Input adjustment ID [0002] directly with the


numeral input switches. (Initial setting of
power train controller)
8) Press [F6].
a The buzzer sounds and the specification
selection is saved.
a Confirm that the displayed specification
code has changed from [1 x 1] to [111].

D375A-6
(01)

DRAFT
Electrial system
Adjustment method when controller has been replaced

9) Press [F5] to return to the adjustment ID input


screen.
10) Input adjustment ID [0031] directly with the
numeral input switches. (Initial setting of
work equipment controller)
11) Press [F6].
a The buzzer sounds and the specification
selection is saved.
a Ensure that the displayed specification
code has changed from [2 x 2] to [222].

3) Press [F3] to select "ON" and press [F6] to


settle the selection.

12) Press [F5] to return to the adjustment ID


input screen.
13) Turn the starting switch to the OFF position
and wait for approx. 30 seconds.
a It takes approx. 30 seconds to shut down
the controller completely after the battery
relay is turned OFF.
14) Turn the starting switch to the ON position
again.
a The machine monitor lights up and displays normally.
a The engine can be started now.

3. Shoe slip control setting


a Set this item after the machine monitor was
replaced, too.
1) Input "86" with the numeral input switches
and press [F6] in the "Service menu" screen.
2) Press [F3] to select "ON" and press [F6] to
settle the selection.

2. VHMS device setting (VHMS specification)


a Set this item after the machine monitor was
replaced, too.
a Since the VHMS device is not installed in the
default setting, be sure to set this item if the
machine has the VHMS specification.
1) Set the machine monitor in the service mode.
2) Select "13 VHMS Setting" in the "Service
menu" screen.

D375A-6
(01)

30-141

DRAFT
Electrial system
Adjustment method when controller has been replaced

4. Prelube setting
a Set this item after the machine monitor was
replaced, too.
1) Input "87" with the numeral input switches
and press [F6] in the "Service menu" screen.
2) Press [F3] to select "ON" and press [F6] to
settle the selection.

4) Check to see if there is any failure code being


indicated. If there is not any, delete all the
recorded failure codes.
a If any active failure codes exist, eliminate
the cause of the incident by troubleshooting then carry out steps 5 and 6 again.
5. Turning power on again
Turn the starting switch to the OFF position and
turn it to the ON position again about 1 minute
after (the battery relay is turned OFF).
6. Checking failure codes
1) Set the machine monitor in the service mode.
2) Select "02 Failure history" on the "Service
menu" screen.

a Precautions after replacing controller:


If any controller is replaced, the service
meter in the oil and filter maintenance
mode is reset to 0.
As a result, the replacement period
displayed on the monitor panel may be
different from the actual operating hours.
To solve this problem, determine the first
replacement periods of the oils and filters
after the replacement of the controller
according to the replacement periods
recorded before the replacement of the
controller.

3) Press [F3] or [F4] to select "02 Electrical


system failure history" and press [F6] to
settle the selection.

30-142

D375A-6
(01)

DRAFT
Electrial system
Adjustment method when controller has been replaced

7. Work equipment specification selection


1) Select "07 Adjustment" in the "Service menu"
screen.

11. IP correction value check (Check of correction


value of electric current)
a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 7845
12. Trigger teaching value check
a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 7847

2) Input adjustment ID [0004] directly with the


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

13. Steering lever neutral position adjustment


a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 1012
14. Steering lever leftmost position adjustment
a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 1013
15. Steering lever rightmost position adjustment
a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 1014
16. Shoe slip control specification setting
a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 0036

8. Brake pedal potentiometer initial correction


a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 0005

17. Travel lever code setting


(For machines with non-standard travel lever
only)
a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 0041

9. Pitch angle sensor standard setting


a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 0009
10. IP automatic correction and trigger automatic initial teaching
a For details, see "Adjustment" function of
"Special functions of machine monitor
(EMMS)".
q Adjustment ID: 7842
D375A-6
(03)

30-143
30-157

DRAFT
Electrial system
Preparation work for troubleshooting of electrical system

Preparation work for troubleshooting of electrical system


a When performing troubleshooting for an electrical circuit related to the machine monitor, engine
controller, work equipment controller, power
train controller, VHMS controller, or ORBCOMM
terminal, expose the related connectors according to the following procedure.

3) Insert or connect test T-adapters into or to


connectors CM01 and CM02 on the back
side of the machine monitor.

1. Machine monitor
1) Remove cover (1).

2. Engine controller
1) Open covers (4) and (5) on the left side of the
engine.

2) Remove 4 mounting bolts (2) and pull out


machine monitor (3) toward this side.

30-144

D375A-6
(01)

DRAFT
Electrial system
Preparation work for troubleshooting of electrical system

2) Remove engine controller covers (6) and (7).

3) Insert or connect the diagnostic T-adapter in


or to the connector (ENG, EGC2, EGC3) of
engine controller (8).
a When disconnecting the connector, loosen its screw.
a When returning the connector to the previous condition, tighten the screw to the
following torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}

In order to prevent malfunction and mistaken system error warning, be sure to


completely remove foreign object (b)
such as sand, dust, water, etc., from inside of controller side connector (a) with
air blow etc., before connecting it to the
harness connector.

D375A-6
(01)

30-145

DRAFT
Electrial system
Preparation work for troubleshooting for electrical equipment system

3. Work equipment controller


1) Slide the operator's seat to the front end and
fold the seat back forward.
2) Remove cover (9).

4. Power train controller


1) Slide the operator's seat to the front end and
fold the seat back forward.
2) Remove cover (9).

3) Remove the mounting bolts of work equipment controller (10).

3) Remove the mounting bolts of power train


controller (11).

4) Insert or connect test T-adapters into or to


connectors WECN1, WECN2 and WECN3.
a Since the connectors are secured with
screws, loosen those screws before disconnecting.
a When returning the connector to the previous condition, tighten the screw to the
following torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}

4) Insert or connect test T-adapters into or to


connectors PTCN1, PTCN2 and PTCN3.
a Since the connectors are secured with
screws, loosen those screws before disconnecting.
a When returning the connector to the previous condition, tighten the screw to the
following torque.
3 Screw: 3 1 Nm {0.3 0.1 kgm}

30-160
30-146

D375A-6
(03)

Electrical system
Preparation work for troubleshooting for electrical equipment system

5. VHMS controller (VHMS specification)


1) Open the cover on the left side of the floor
and remove cover (12).
2) Insert or connect troubleshooting T-adapters
into V1, V2A, V2B, V3A, V3B, V4A and V4B
connectors of VHMS controller (13).
a If it is difficult to remove and install the
connectors, remove the controller for the
ease of work.

6. ORBCOMM terminal
1) Remove seat belt buckle (14) and remove
cover (15).

D375A-6
(06)

2) Remove the mounting bolts of ORBCOMM


terminal (16) and pull out the terminal.

3) Insert or connect test T-adapter into or to


connector KOM1.
a Since the connectors are secured with
screws, loosen those screws before disconnecting.
a When returning the connector to the previous condition, tighten the screw to the
following torque.
3 Screw:3 1 Nm {0.3 0.1 kgm}

30-147

DRAFT
Electrial system
Inspection procedure of diode

Inspection procedure of diode


a The direction of continuity of diode is marked on
the surface of the diode.

1. When using digital tester


1) Set the tester in the diode range and read the
indicated value.
a When an ordinary circuit tester is used,
the voltage of the internal battery is indicated.
2) Put the red probe (+) of the test lead to the
anode (P) of and the black probe () to the
cathode (N) of diode, and confirm the indicated value.
3) Evaluate the condition of the diode by the
indicated value.
q Indicated value remains unchanged:
Conduction is absent (Failure)
q The indicated value changes: The diode
has conductivity (Normal) (See a below.)
Note: In the case of silicon diode, the value
between 460 600 mV is displayed.
q Displayed value becomes 0 or near 0 :
Short-circuiting of diode internal part (defect)

30-148

2. When using analog tester


1) Set the tester in the resistance range.
2) Apply the leads of the tester as explainedbelow and check the movement of the
pointer.
1] Set red (+) test lead to diode anode (P)
side and black () test lead to cathode (N)
side.
2] Set red (+) test lead to diode cathode (N)
side and black () test lead to anode (P)
side.
3) Evaluate the condition of the diode by the
movement of the pointer.
q Needle does not deflect with connection i)
but deflects with connection ii): Normal.
(However deflection range (resistance
value) varies depending on the type of
tester and testing range.)
q Needle deflects with both connection i)
and ii): Defective (internal short circuit)
q Needle does not deflect with either connection 1] or 2]: Defective (internal disconnection)

D375A-6
(01)

DRAFT
Electrial system
Handling of optional devices

Handling of optional devices


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

4. Connecting C signal of starting switch


When starting switch signal C (starting signal) is
necessary to an optional device such as prelube
device, take it out of the following connector pin.
q CN-PRS (2-pole heavy duty wire connector)
a Remove the connector installed when the
machine was delivered and connect pin (1) to
the final starting signal output point of the
prelube device and connect pin (2) to the input signal point from the starting switch.
5. Connecting external power source
If an external power source is necessary,
connect it through the following connectors.
q CN-800 (Plug connector):
Used for device in cab
q CN-810 (Plug connector):
Used for device out of cab
a A 20A fuse is installed on the upstream side
of these connectors.

2. Input of engine stop signal


If the engine needs to be stopped with the
starting switch in the ON position for an optional
device such as the engine emergency stop
system, use the circuit of the following connector
pin.
q Pin [A] of CN-ESD (3-pole heavy duty wire
connector)
a Before using this circuit, be sure to notify your
Komatsu distributor.
3. Inputting engine low-idle command
If it is required to keep the engine speed at low
idle for an optional device such as the engine
protector, use the circuit of the following
connector pin.
q Pin (C) of CN-ESD (3-pole heavy duty wire
connector)
a Before using this circuit, be sure to notify your
Komatsu distributor.

D375A-6
(01)

30-149

DRAFT
Electrial system
Request for opening ORBCOMM terminal

Request for opening ORBCOMM terminal


a If the machine is equipped with ORBCOMM, fill
in the "Request for opening VHMS ORBCOMM
terminal" and send it by fax or mail to "KOMATSU KOMTRAX SUPPORT CENTER" before initializing the VHMS controller.
a Initialize the VHMS controller after the opening
notification is received from "KOMATSU
KOMTRAX SUPPORT CENTER".
a If the ORBCOMM antenna is installed and the
starting switch is turned to the ON position before the opening notification is received, the ORBCOMM terminal transmits radio waves and
ORBCOMM CO. LTD. sends out the stop signal
automatically. In this case, complicated procedures and some time are required to open the
ORBCOMM terminal service again.

30-150

D375A-6
(01)

DRAFT
Electrial system
Request for opening ORBCOMM terminal

D375A-6
(03)

30-151
30-165

DRAFT
Electrial system
Initialization procedures for VHMS controller

Initialization procedures for VHMS controller


a Initialization tools for VHMS controller
SymPart No.
bol
1 799-608-3211
799-608-322
2
0
Z
Commer3
cially available

Part name
Discket
Wiring harness
Notebook type personal computer
:Windows98/2000/Me/XP/VISTA
(*) [With RS232C terminal]

*:VHMS setting tool Ver.3.06.00.03 or later, VHMS


analysis tool Ver.3.05.00.00 or later.
a Before starting full operation after completion of
local assembly or before resuming operation after storage for a long period, initialize the VHMS
controller according to the following procedure.
a Machine data collected with the VHMS controller
are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS
controller consistently. If it is not set correctly,
data will not be taken into the WebCARE and
data in the VHMS controller may not be utilized.
Accordingly, be sure to carry out the initialization.
a For the method of installing the VHMS Initialization Program to the personal computer, refer to
the Operation and Maintenance Manual contained in the package of diskette Z1.
a Since the service menu of the machine monitor
will be used in the following procedure, read
"Special functions of machine monitor (EMMS)"
and understand the operating procedure in advance.
a The initial setting procedure is described in the
ORBCOM installation specification and the ORBCOM-less specification. When using the ORBCOM installation specification, implement the
procedures needed for VHMS alone, bypassing
those prepared only for ORBCOM installation
specification.
a During the initialization work, confirm each work
according to the "VHMS Initialization Work
Checklist".

30-152

1. Check of machine information, engine information and controller information


a This step is a work performed on the whole
machine.
Check and record the machine information,
engine information, VHMS controller information and ORBCOMM terminal information.
NO
1
2
3
4
5
6

Information to be checked
Model name
Machine serial No.
Current service meter reading
Engine serial No.
Transmission serial No.
VHMS controller serial No.
ORBCOMM terminal serial No.
7
[Only for machines equipped with ORBCOM]

a VHMS controller (1) is in the control box on


the left side of the floor and ORBCOMM terminal (2) is in the control box on the right side
of the floor.

D375A-6
(01)

DRAFT
Electrial system
Initialization procedures for VHMS controller

2. Connection of personal computer


1) Make sure that the starting switch is in the
OFF position.
k Be sure to turn off the starting switch
before connecting or disconnecting
the personal computer.
2) Connect personal computer Z3 and download connectors (VDW) and (DL1) by wiring
harness Z2.
a The download connectors are installed to
the following places.
q VDW: Under left rear of operator seat
q DL1: Right rear of machine body (Side
of backup lamp)
a Connect the personal computer to the
RS232C terminal.

3. Check of operation and satellite capturing condition of VHMS controller


a This step is a work performed in the operator's cab.
a Check of satellite capturing condition is necessary o only [ORBCOMM specification].
[Method of checking with monitoring function](Monitoring code: 99003)
1) Turn the starting switch to the ON position.
2) Set the machine monitor to display the
service menu.
a For the operating method, see "Special
functions of machine monitor (EMMS)".

a Execute initialization of VHMS from the


connector in the cab.
a Use the ground download connector for
only downloading.

D375A-6
(01)

3) Select "01 Monitoring".

30-153

DRAFT
Electrial system
Initialization procedures for VHMS controller

4) Input monitoring code 99003 directly with the


numeral input switches.
a The communication condition of the ORBCOMM terminal is displayed.

[Method of checking with monitoring function]


(Monitoring code: 20300)
1) Input monitoring code 20300 directly with the
numeral input switches.
a The procedure up to inputting of the monitoring code is the same as the above section.

2) At least 3 minutes after the starting switch is


turned to the ON position, check the communication condition of the ORBCOMM terminal
by the display condition of the decimal point
(indicated with the arrow) of the machine
monitor.

Decimal
point

Condition
q

OFF

q
q

ON

q
q
q

Blinking

q
q

Power is not supplied to ORBCOMM controller.


Communication line to VHMS controller is
abnormal.
Satellite is not captured.
Power is supplied to ORBCOMM controller.
Communication line to VHMS controller is
normal.
Power is supplied to ORBCOMM controller.
Communication line to VHMS controller is
normal.
Satellite is captured.

[Method of checking with VHMS controller]


1) Turn the starting switch to the ON position.
2) The 7-segment LED (indicated with the
arrow) of the VHMS controller flashes and
rotates, and then counts up.

30-154

D375A-6
(01)

DRAFT
Electrial system
Initialization procedures for VHMS controller

3) Confirm that the ORBCOMM terminal has


captured the communication satellite by
checking that the decimal point (indicated
with the arrow) of the 7-segment LED is
flashing.
a The ORBCOMM terminal may take time
to capture the satellite, depending on the
strength of the signals from the satellite.

4. Startup of VHMS initialization tool


a This step is a work performed in the operator's cab (on the personal computer).
1) Turn on the personal computer and start the
OS.
2) Click the icon of [VHMS Initialization Tool] on
the personal computer screen to start the
VHMS initialization tool.
Important
a The setting screen varies with the version
No. of the VHMS setting tool.
a When using a tool before Ver. 3.5.2.1
(CD-ROM), set the VHMS in step 5.
a When using an updated tool (Ver. 3.5.2.1
or after), set the VHMS in step 6.
a It is recommended to download the latest
VHMS setting tool from the WebCARE
and update your tool.
(Related
material:
Servicemate
SMP-623)
3) Input the 10-digit service ID in [Service ID].
a Service ID: 7826147000
4) Select [Data clear and Set up] in the [Select
Function] column.
5) Press the [OK] button to go to the setup
screen.

5. Initialization of VHMS controller (Tool before


Ver. 3.5.2.1)
a This step is a work performed in the operator's cab (on the personal computer).
a When initializing, do not change the data of
service meter [SMR].
[Machine Information]
1) Open the [Machine information] tab.
a The [Machine information] tab is displayed first in the [Data clear and Set up]
menu.
2) Check all the data.

3) If information in the [Date/Time] box is not


correct, change it according to the following
procedures:

D375A-6
(01)

30-155

DRAFT
Electrial system
Initialization procedures for VHMS controller

1] Press [Edit] button (1) on the right lower


part of the [Date/Time] box to display the
correction screen.
2] Correct the information and press the
[OK] button.

4) If information in the [Machine information]


box is not correct, change it according to the
following procedures:
1] Press the [Edit] button (2) on the right
lower part of the [Machine information]
box to display the correction screen.
2] Correct the information and press the
[OK] button.

5) After checking/changing all the data in


[Machine information], press [Apply] button
(3) to settle the setting.
a Press the [Apply] button (3), and the
screen for checking the setting will appear. Check the setting again and press
the [OK] button if the setting is correct.
a In case of the ORBCOMM Specification,
execute [Communication Setting] first
and then settle the setting.

30-156

D375A-6
(01)

DRAFT
Electrial system
Initialization procedures for VHMS controller

[Communication Setting] (For


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

8) To change the setting in [SHORT FAULT


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

D375A-6
(01)

9) To change setting in [SHORT TREND ANALYSIS], follow the procedures below:


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

10)To change the setting of [Satellite Setting],


follow the procedure below.
1] Press the [Edit] button in the [Satellite
Setting] block to display the setting
screen.
2] Set the GCC Code to the applicable area
and then press the [OK] button.

30-157

Electrical system
Initialization procedures for VHMS controller

GCC
Code
1

120

130

Area
N.America (*1)
C.S.Americas
Faroe Islands
Europe (*2)
Middle East
Asia (*3)
Africa
Oceania CIS
Japan

Remarks
*1: Except U.S. Territories in
Micronesia and Midway Island

*2 Except Faroe Islands


*3 Except Japan

a If the combination of the country name


and code in the list box displayed by the
setting tool is different from the above table, select the GCC code in the table or
input the value through the keyboard.
11)After checking/changing all the data in
[Communication Setting], press [Apply]
button to enter the setting.
a If the [Apply] button is pressed, the
screen for checking the setting appears.
Check the setting again and press the
[OK] button if the setting is correct.

6. Initialization of VHMS controller (Ver. 3.5.2.1


or after)
a This step is a work performed in the operator's cab (on the personal computer).
a When initializing, do not change the data of
service meter [SMR].
1) Select [VHMS Setting] and press the "Next"
button.

2) Select [Set up & All clear] and press the


"Next" button.
12)After checking/changing the data of [Machine
Information] and [Communication Setting],
press the [Exit] button at the lower right
portion of the screen to finish [VHMS Initial
setting Tool].

30-158

D375A-6
(06)

DRAFT
Electrial system
Initialization procedures for VHMS controller

3) Check the machine information. If it does not


need to be corrected, press the "Next"
button.

4) Select the time zone.


5) Input the local time.
6) If the DST (Daylight Saving Time) is used
now, select it and press the "Next" button.
a If the DST is selected, the clock is advanced 1 hour automatically, thus the
time must be corrected again.

a If the VHMS was installed additionally,


the information of [Serial No.] etc. must
be input.
7) Set the GCC Code to the applicable area and
then press the "Next" button.
GCC
Code
1

120

130

Area
N.America (*1)
C.S.Americas
Faroe Islands
Europe (*2)
Middle East
Asia (*3)
Africa
Oceania
CIS
Japan

Remarks
*1: Except U.S. Territories in
Micronesia and Midway Island

*2: Except Faroe Islands


*3: Except Japan

a If the combination of the country name


and code in the list box displayed by the
setting tool is different from the above table, select the GCC code in the table or
input the value through the keyboard.

D375A-6
(03)

30-159
30-173

DRAFT
Electrial system
Initialization procedures for VHMS controller

8) The contents of the setting are displayed


finally. If there is not a problem, press the
"Apply" button.

9) The system asks you if you save the data


before changing the setting. If you do not
need to save, select "NO".

10)After finishing the work of changing the


contents of initialization, press the "OK"
button to finish the program.

30-160

D375A-6
(01)

DRAFT
Electrial system
Initialization procedures for VHMS controller

7. Downloading of set data


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

2) When using download connector (VDW) in


the cab, set the starting switch in the ON
position.
3) When using ground download connector
(DL1), turn switch (3) ON.
a The green LED lights up.
4) Operate the icon of [VHMS Technical Analysis Tool] on the personal computer to start
the VHMS technical analysis tool.

a Download connector (VDW) in the cab is


installed to the left rear lower part of the
operator's seat.

a The ground download connector DL1 is


installed to the side of the backup lamp at
the rear right of the machine.

30-176
30-166

a Input [User Name] and [Password].


a For the operation procedures, refer to the
Operation and Maintenance Manual for
VHMS Technical Analysis Tool.

5) Use the [Download] function to download the


data recorded in the VHMS controller to the
personal computer.
a For the operation procedures, refer to the
Operation and Maintenance Manual for
VHMS Technical Analysis Tool.
a Make sure that downloading has completed before proceeding to the next step.

D375A-6
(03)

DRAFT
Electrial system
Initialization procedures for VHMS controller

8. Check of downloaded data


a This step is a work performed in the operator's cab (on the personal computer).
1) Check the set data with the [View] function.
a For the operation procedures, refer to the
Operation and Maintenance Manual for
VHMS Technical Analysis Tool.
a Make sure that the [MFA0] code at the
time when the snapshot was operated is
displayed in [Fault History].
a Make sure that the snap shot data is recorded.

3) If the data was downloaded in the cab,


disconnect wiring harness Z2 from download
connector (VDW).

4) If the data was downloaded on the ground,


turn switch (3) OFF and disconnect wiring
harness Z2 from download connector (DL1).

2) After checking the set data, terminate [VHMS


Technical Analysis Tool].
9. Disconnection of Personal Computer
1) Make sure that the starting switch is in the
OFF position.
k Be sure to turn off the starting switch
before connecting or disconnecting
the personal computer.
2) Finish the OS of the personal computer and
then turn the personal computer OFF.

D375A-6
(03)

30-167
30-177

DRAFT
Electrial system
Initialization procedures for VHMS controller

10. Report to Komatsu


After completing steps 1 to 9 successfully, send
the "VHMS/WebCARE setting notification form"
to VHMS/WebCARE Support Center of
Komatsu, Tokyo.
a Since Komatsu has to set the receiving side
of the satellite communication, be sure to inform Komatsu of the completion of the setting.
a Send the VHMS data by Notes (LAN) or
E-mail (WAN).
a When using the KOMTRAX functions on the
machine equipped with the ORBCOMM,
complete the sign-up test on the machine
side and enter the use of the KOMTRAX
functions in the "VHMS/WebCARE setting
notification form".
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)
E-mail: webcare@komatsu.co.jp

30-178
30-168

D375A-6
(03)

DRAFT
Electrial system
Initialization procedures for VHMS controller

[For storage]
VHMS initial setting work check sheet
Setting step

Date of setting:
DB/branch
name:
Data entered by:
Check item

Result

Check of nameplates of chassis and


components

Model name
Serial No.
Engine serial No.
Transmission controller serial No.
VHMS controller serial No.

Connection of personal computer and


VHMS controller

Is connection made securely?

yes

no

3 Check of operation VHMS controller

Is operation normal?
(Decimal counting up must be displayed after rotation.)

yes

no

4 Starting of VHMS initialization Tool

Is setting tool set in "Data Clear and Set up" mode?

yes

no

Initialization of VHMS controller


(Setting of machine information)
5
Set basic information of machine to
VHMS controller in this step.

Is model name correct?


Is machine serial No. input correctly?
Is engine serial No. input correctly?
Is today's date displayed?
Does clock indicate present time?
Is SMR input correctly?

yes
yes
yes
yes
yes
yes

no
no
no
no
no
no

6 Saving of set items

Is LED (7-segment) turned OFF?

yes

no

7 Check of VHMS function

Does LED operate normally?

yes

no

8 Execution of Quick Pm Clinic

Are service mode "SNAPSHOT" selected and is switch


pressed?

yes

no

9 Saving operation of VHMS

Is LED (7-segment) turned OFF?

yes

no

10 Downloading

Does LED operate normally?

yes

no

Are all files downloaded?


The time downloaded (Reference wrist watch)
11 Check of downloaded data

12 Saving operation of VHMS

D375A-6
(01)

yes no
Hour, minute:

[Check of data]
Is there MFA0 error in Fault History?
Are SMR and time in Fault History matched to set values?
Are all data of Snap Shot prepared?

yes
yes
yes

no
no
no

Is LED (7-segment) turned OFF?

yes

no

30-169

DRAFT
Electrial system
Initialization procedures for VHMS controller

[For keeping]
ORBCOMM Station Establishment Check
Sheet
Setting step

Date of setting:
DB/branch name:
Data entered by:
Check item

Check of nameplates of chassis


and components

Model name
Serial No.
Engine serial No.
Transmission serial No.
VHMS controller serial No.
ORBCOMM controller serial No.

Connection of personal computer


and VHMS controller

Is connection made securely?

Check of operation VHMS control- Is operation normal?


ler
(Counting up must be displayed after rotation.)

4 Starting of VHMS Initialization Tool Is setting tool set in "Set up" mode?

Initial setting of VHMS controller


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

2. Setting of start of communication


6 Saving of set items
7

Enter set value of S.Fault History.


Execution of communication
Number of communication (Default: 8)
Enter set value of S. Trend Analysis.
Execution of communication
Interval (Default: 20H)
Enter set value of S. Payload data (If PLM is installed).
Execution of communication
Time to start collection
Collection interval (Number of days)

yes

no

yes

no

yes

no

On
hrs

Off

On
hrs

Off

On

Off
day

Is GCC code set? (130 for Japan)

yes

no

Is LED (7-segment) turned OFF after saving operation?

yes

no

yes

no

Check of operation of ORBCOMM How is display of decimal point on VHMS monitor (7-segment)?
controller
(Off, On, long/short flashing)

30-170

Result

D375A-6
(01)

DRAFT
Electrial system
Initialization procedures for VHMS controller

D375A-6
(01)

30-171

Electrical system
Using method of KOMTRAX functions of ORBCOMM terminal

Using method of KOMTRAX functions of ORBCOMM terminal


a The ORBCOMM terminal equipped with the
KOMTRAX function can display the machine on
the control screen of the KOMTRAX system.
a Whether the ORBCOMM terminal has the
KOMTRAX functions can be checked by the part
No. of the ORBCOMM terminal.
a When using the KOMTRAX functions, perform
the following procedure.
1. Make the request for opening the ORBCOMM
terminal and receive the opening notification.
a See "Request for opening ORBCOMM terminal".
2. Initialize the VHMS controller and set the GCC
code of the machine location.
a See "Initialization procedure for VHMS controller".
3. Perform the sign-up test on the machine side.
a Perform the sign-up test in an open outdoor
place.
a If the sign-up test is performed in an indoor
place where the satellite radio waves are
blocked, it may not be completed.
a It may take time to complete the sign-up test,
depending on the condition of receiving signals from the ORBCOMM communication
satellite and GPS satellite.
1) Check that the VHMS controller, ORBCOMM
terminal, ORBCOMM antenna and GPS
antenna are connected to the wiring harness
of the machine.
2) Turn the starting switch to the ON position.
3) Wait until LED1 lights up.
a LED1 keeps flashing until the sign-up test
is completed.

30-172

30-181

a The ORBCOMM terminal executes the


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

D375A-6
(06)

Electrical system
Using method of KOMTRAX functions of ORBCOMM terminal

[LED display]
(1) LED-Green
(2) LED-red

(3) LED Yellow


(4) LED Green

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

(5) LED Red


(6) LED Red
(7) 7 segment

Unused
Unused

(8) Dot

GPS satellite capture state

OFF: OFF
Kept OFF
Kept OFF
Number of mails waiting to be sent (Max. of
Satellite not captured: OFF
Satellite captured: ON

* Flashing interval
Quick flashing: Cycle of 1 sec (ON for 0.5 sec and OFF for 0.5 sec repeatedly)
Slow flashing: Cycle of 4 sec (ON for 0.5 sec and OFF for 1.5 sec repeatedly)

D375A-6
(06)

30-173

DRAFT
Electrial system
Using method of KOMTRAX functions of ORBCOMM terminal

4. Apply for starting to use.


1) Notify the VHMS/WebCARE operations
administrator of the following information of
the machine which has completed the station
set-up check.
q Model, model No. and serial No. of machine
q Part No. and serial No. of ORBCOMM terminal
q Reading of service meter when sign-up
test was completed (0.1 h unit)
2) Fill in the "VHMS/WebCARE setting notification form" and enter "Use" in the column of
"Use of KOMTRAX Service".
3) Send the "VHMS/WebCARE setting notification form" to VHMS/WebCARE Support
Center in Komatsu Head Office.
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)
E-mail: webcare@komatsu.co.jp

4) The KOMTRAX operations administrator


registers the machine using the KOMTRAX
client personal computer.
a For the registration procedure, see the
"Global KOMTRAX Web Reference Manual (For Key Person)".

30-174

D375A-6
(01)

DRAFT
Electrial system
Precautions for replacing VHMS controller

Precautions for replacing VHMS controller


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

*:VHMS setting tool Ver.3.06.00.03 or later, VHMS


analysis tool Ver.3.05.00.00 or later.
a When the VHMS controller needs to be replaced, set it before removing it and the installed
new VHMS controller according to the following
procedure.
a Machine data collected with the VHMS controller
are stored and managed in WebCARE database. To process the data smoothly on the WebCARE, it is necessary to set the VHMS
controller consistently. If it is not set correctly,
data will not be taken into the WebCARE and
data in the VHMS controller may not be utilized.
Accordingly, be sure to carry out the initialization.
a During the initialization work, confirm each work
according to the "VHMS Initialization Work
Checklist".
[Work before replacing VHMS controller]
1. Downloading of remaining data
a This step is a work performed in the operator's cab (on the personal computer).
a Using the [Download] function, download the
data currently recorded in the VHMS controller to the personal computer.
a For the operating procedures, see Initialization procedures for VHMS controller, "8.
Downloading of set data".

D375A-6
(01)

2. Check, saving and writing of information set in


VHMS controller (Before Ver. 3.5.2.1)
a This step is a work performed in the operator's cab (on the personal computer).
a Transfer the set data of the VHMS controller
to be replaced to the personal computer and
then write it in the newly installed VHMS controller.
2-1. Check and saving of information set in
VHMS controller to be replaced.
1) Connect the personal computer and start the
VHMS technical analysis tool.
a See "Initialization procedures for VHMS
controller".
2) Select "Save/Load" and press the "OK"
button.

3) Check all the information before replacing


the VHMS controller.
4) Select [Save] from [File] in the menu.

30-175

DRAFT
Electrial system
Precautions for replacing VHMS controller

2-2. Writing of set information in new VHMS


controller
1) Connect the personal computer again and
start the VHMS technical analysis tool.
a See "Initialization procedures for VHMS
controller".
2) Select "Save/Load" and press the "OK"
button.
5) Check the information again and press the
"OK" button to save it.

3) Select [Load] from [File] in the menu.


6) Select [Exit] from [File] in the menu to finish
the VHMS setting tool.
7) Disconnect the personal computer.
a See Initialization procedures for VHMS
controller, "9. Disconnection of Personal
Computer".
8) Turn the personal computer OFF.
9) Replace the VHMS controller.

30-176

D375A-6
(01)

DRAFT
Electrial system
Precautions for replacing VHMS controller

4) The saved information is displayed. Press


the "OK" button.

7) After setting the time, press the "OK" button.

8) Press the [Apply] button, and the contents of


the setting are displayed. Check the contents
again and press the [OK] button if there is not
a problem.

5) The saved information is displayed on


another screen.
6) Press the [Edit] button to set the time.

D375A-6
(01)

30-177

DRAFT
Electrial system
Precautions for replacing VHMS controller

9) The system asks you if you will save the


previous data. Press the "NO" button.
a Usually, you do not need to save the previous data.

3. Check, saving and writing of information set in


VHMS controller (Ver.3.5.2.1 or later)
a This step is a work performed in the operator's cab (on the personal computer).
a Transfer the set data of the VHMS controller to be replaced to the personal computer and then write it in the newly
installed VHMS controller.
3-1. Check and saving of information set in
VHMS controller to be replaced.
1) Connect the personal computer and start the
VHMS technical analysis tool.
a See "Initialization procedures for VHMS
controller".
2) Select [When VHMS needs to be replaced]
and press the "Next" button.

10)Select [Exit] from [File] in the menu to finish


the VHMS setting tool.

3) Select [Save Current Setting before replacement of VHMS controller] and press the
"Next" button.

30-178

D375A-6
(01)

DRAFT
Electrial system
Precautions for replacing VHMS controller

4) Check all the information before replacing


the VHMS controller and press the "Save"
button.

3) Select [Use Previous setting after replacement of VHMS controller] and press the
"Next" button.

5) Select [Exit] from [File] in the menu to finish


the VHMS setting tool.
6) Disconnect the personal computer.
a See Initialization procedures for VHMS
controller, "9. Disconnection of Personal
Computer".
7) Turn the personal computer OFF.
8) Replace the VHMS controller.

4) The saved information is displayed. Press


the "Next" button.

3-2. Writing of set information in new VHMS


controller
1) Connect the personal computer again and
start the VHMS technical analysis tool.
a See "Initialization procedures for VHMS
controller".
2) Select [When VHMS needs to be replaced]
and press the "Next" button.
5) Set the time and press the "Apply" button.

D375A-6
(01)

30-179

DRAFT
Electrial system
Precautions for replacing VHMS controller

6) The system asks you if you will save the


previous data. Press the "NO" button.
a Usually, you do not need to save the previous data.

[Work after replacing VHMS controller]


a After replacing the VHMS controller, carry out
initialization according to the "Initialization Procedure for VHMS Controller".
a Change the data to the information recorded before the VHMS controller was replaced. (Input
the date and time when the VHMS controller was
replaced.)
a After completing the setting after the replacement, send the check sheet to VHMS/WebCARE Support Center of Komatsu, Tokyo.
a Send the data downloaded before and after replacing the VHMS controller by Notes (LAN) or
E-mail (WAN).
Komatsu VHMS/WebCARE Support Center
2-3-6, Akasaka Minato-ku Tokyo, Japan
FAX: 81-3-5561-4766 (from outside of Japan)

7) The above completes modification of the


setting. Press [OK] button to end the VHMS
initial setting tool.

30-180

E-mail: webcare@komatsu.co.jp

D375A-6
(01)

DRAFT
Pm Clinic service
Pm Clinic service

Pm Clinic service
Pm Clinic service
Model
D375A6 #60001

Serial No.

Service meter
h

User name

Date of inspection
/
/

Serviceman

Specifications
Blade
Semi U blade
U blade

Blade tilt
Single tilt blade
Dual tilt blade

Attachment
Multishank ripper
Variable giant ripper
Counter weight (
kg)
Others

Shoe width
610 mm
710 mm
810 mm
Others

Operating conditions
Construction
Type of soil (specific gravity)
Construction, civil engineering Rock
Roads
Gravel
Tunnels
Sand

Clay

Quarry, mine
Coal
Gold
Limestone

Type of work
Dozing
Side cutting
Ripping
Travel

%
%
%
%

Existence of abnormalities
Oil, coolant level check
Engine coolant level
Engine oil level
Hydraulic oil level

When necessary
Power train
Final drive

Damper case
(
)

Ambient temperature
Max.
Min.

Height above sea level

m
Operator's opinion
Visual check results

[
Content:
[
Content:

Failure code history


[
Content:
[
Content:

Operating mode
q Working mode: P- or E-mode
q Gear shift mode: Auto or Manual
q Preset: F ,R
Comment

D375A-6
(03)

30-181
30-191

Pm Clinic
Pm Clinic service

30-191

Pm Clinic measurement item or specification of the D375A6


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

Specifications
STD
Pm clinic
VHMS

Engine speed

Engine oil pressure Exhaust temperature

Q
Q
Q

Q
Q
Q

Torque converter inlet


pressure

Q
Q
Q

Torque converter outlet


pressure

Q
Q
Q

Blowby

Boost pressure

x
x

Q
Q
Q

E
Q

Power train oil circuit


Torque converter stator
L/U
clutch pressure

E
E
E

Steering pressure

Brake pressure

E
E
E

E
E
E

E
E
E

Power train oil circuit


Transmission
Specificamain relief
tions
pressure
STD
E
Pm clinic
E
VHMS
Q

1st

2nd

3rd

E
E
E

E
E
E

E
E
E

E
E
E

E
E
E

Work equipment circuit


Specifications
STD
Pm clinic
VHMS

30-182

Transmission
lubricating oil
pressure

E
E
E

Fan circuit

Control source pressure

Pump pressure

Engine speed

E
E
E

E
Q
Q

Q
Q
Q

D375A-6
(06)

Pm Clinic
Pm Clinic service

Testing points for Pm clinic (1/3)

30-192

For the measurement procedures, see the following pages.


*1. Engine speed: "Testing engine speed"
*2. Blowby pressure: "Testing blowby pressure"
*3. Engine oil pressure: "Testing engine oil pressure"
*4. Boost pressure: "Testing intake air pressure (boost pressure)"
*5. Exhaust gas temperature: "Testing exhaust temperature"

D375A-6
(06)

30-183

Pm Clinic
Pm Clinic service

Testing points for Pm clinic (2/3)

30-193

For the measurement procedures, see the following pages.


*6. Measurement related to torque converter: "Testing power train oil pressure"
*7. Measurement related to transmission: "Testing power train oil pressure"
*8. Measurement related to steering brake "Testing power train oil pressure"

30-184

D375A-6
(06)

Pm Clinic
Pm Clinic service

Testing points for Pm clinic (3/3)

30-194

For the measurement procedures, see the following pages.


*9. Hydraulic pressure of work equipment: "Measuring and ajusting work equipment oil pressure"
*10. Source pressure of control circuit: "Testing of control circuit main pressure"
*11. Fan speed: "Check of fan speed"

D375A-6
(06)

30-185

DRAFT
Pm Clinic service
Pm Clinic service

Pm Clinic check sheet


Work order No.

D375A6

Date of inspection
/
/

Item

Service meter

Unit

Low idle

Engine speed

Deceleration pedal
depressed

High idle

rpm

Engine

Torque converter stall (Adjustment ID: 0530)


Torque converter stall + Work equipment relief
(ripper raise) (Adjustment ID: 0530)
Blowby pressure

SAE0W30E0S
SAE5W40E0S
SAE10W30DH
SAE15W40DH
Oil temperature:
Min. 70 C

Low idle
Engine oil pressure
High idle
Boost pressure

At torque converter stall

Exhaust temperature

Torque converter stall +


Work equipment relief

Standard
Service limit Test
value for new
OK NG Remarks
value
results
machine
700 800

850 950

1,850 1,900

1,480 1,580

1,450

1,450 1,550

1,400

Max. 3.43
{Max. 350}

Min. 9.41
{Min. 960}

Min. 117.68
{Min. 1.2}

Max. 78.45
{Max. 0.8}

Min. 392.27
{Min. 4.0}

Max. 235.36
{Max. 2.4}

kPa
{mmHg}

Min. 155
{Min. 1,160}

Max. 141
{Max. 1.060}

Max. 700

Min. 730

kPa
{mmH2O}

At torque converter stall

Serviceman
h

Test conditions

Decel

Serial No.

kPa
{kg/cm2}

No. 1, 2 , 3 cylinder
No. 4, 5, 6 cylinder

k For torque converter lockup clutch pressure, set both of the steering clutches to the disengage mode on the machine

monitor and check the pressure.


Item

Test conditions

Unit

Inlet oil pressure

Torque converter

Outlet oil pressure


Lockup clutch pressure
Stator clutch pressure

Engine low idle

Transmission: Neutral

MPa
{kg/cm2}

Inlet oil pressure


Outlet oil pressure
Lockup clutch pressure
Stator clutch pressure
Lockup clutch pressure

Engine high idle

Transmission: F2
(Adjustment ID: 5535)

Engine high idle

Standard
Service limit Test
value for new
OK NG Remarks
value
results
machine
0.03 0.25
{0.3 2.5}
0.03 0.20
{0.3 2.0}
00
{0 0}
2.25 2.87
{23.0 29.3}
0.69 1.05
{7.0 10.7}
0.44 0.70
{4.5 7.0}
00
{0 0}
2.55 2.87
{26.0 29.3}
1.29 1.54
{13.2 15.7}

i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i
i

k For each of the transmission clutch pressures, set both of the steering clutches to the disengage mode on the machine

monitor and check the pressures only in low idle for safety.
Item

Test conditions

Unit

Engine low idle


Main relief pressure

Transmission

Transmission: Neutral
Lubricating oil pressure
F clutch pressure
R clutch pressure
1st clutch pressure
2nd clutch pressure
3rd clutch pressure

30-196
30-186

Engine high idle


Engine high idle

Transmission: F1
(Adjustment ID: 5535)
Transmission: R1
(Adjustment ID: 5535)
Transmission: F1
(Adjustment ID: 5535)
Transmission: F2
(Adjustment ID: 5535)
Transmission: F3
(Adjustment ID: 5535)

Engine low idle


Engine low idle
Engine low idle
Engine low idle
Engine low idle

MPa
{kg/cm2}

Standard
Service limit Test
OK NG Remarks
value for new
value
results
2.48 2.87
{25.3 29.3}
2.68 2.87
{27.3 29.3}
0.08 0.25
{0.8 2.5}
2.25 2.84
{23.0 29.0}
2.25 2.84
{23.0 29.0}
2.06 2.35
{21.0 24.0}
2.25 2.84
{23.0 29.0}
2.25 2.84
{23.0 29.0}

2.38 3.07
{24.3 31.3}
2.58 3.07
{26.3 31.3}
i
i
2.06 3.13
{21.0 31.9}
2.06 3.13
{21.0 31.9}
1.86 2.55
{18.9 26.0}
2.06 3.13
{21.0 31.9}
2.06 3.13
{21.0 31.9}

D375A-6
(03)

DRAFT
Pm Clinic service
Pm Clinic service

Pm Clinic check sheet


Work order No.

D375A6

Date of inspection
/

Item

Service meter

Test conditions

Unit

Engine low idle


Steering clutch & brake

Left brake pressure


Transmission: Neutral
Left clutch pressure
Engine high idle
Left brake pressure

MPa
{kg/cm2}

Right clutch pressure


Engine low idle
Right brake pressure
Transmission: Neutral
Right clutch pressure
Engine high idle
Right brake pressure
Engine at high idle, F2, brake actuated

Hydraulic system

Item

Test conditions

Work equipment
pump
(Unload pressure)

Control lever in NEUEngine high idle


TRAL position

Work equipment
pump

Ripper lift relief or


blade tilt relief

Control circuit source Control lever in NEUpressure


TRAL position

Item
Min. speed
Fan

Engine low idle

Unit

MPa
{kg/cm2}

Engine high idle

Test conditions

Unit

Engine low idle


Fan 100 % mode

Max. speed

Item

Serviceman

Left clutch pressure

Brake performance

Serial No.

Standard value
Service limit
for new
value
machine

Test
results

OK NG Remarks

Test
results

OK NG Remarks

Test
results

OK NG Remarks

Test
results

OK NG Remarks

2.25 2.84
2.2 3.04
{23.0 29.0}
{22.4 31.0}
2.25 2.84
2.2 3.04
{23.0 29.0}
{22.4 31.0}
2.55 2.87
2.4 3.07
{26.0 29.3}
{24.4 31.3}
2.55 2.87
2.4 3.07
{26.0 29.3}
{24.4 31.3}
2.25 2.84
2.2 3.04
{23.0 29.0}
{22.4 31.0}
2.25 2.84
2.2 3.04
{23.0 29.0}
{22.4 31.0}
2.55 2.87
2.4 3.07
{26.0 29.3}
{24.4 31.3}
2.55 2.87
2.4 3.07
{26.0 29.3}
{24.4 31.3}
Machine must not move

Standard value
Service limit
for new
value
machine
2.45 3.82
{25 39}

2.45 3.82
{25 39}

27.5 29.4
{280 300}
27.5 29.4
{280 300}
3.43 4.12
{35 42}

Min. 26.5
{Min. 270}
Min. 26.5
{Min. 270}
Min. 3.1
{Min. 32}

Standard value
Service limit
for new
value
machine
250 450

1,185 1,235

Max. 1,110

rpm
Engine high idle

Test conditions

Unit

Standard value
Service limit
for new
value
machine

Engine low idle

7 13

20

Engine high idle

3.7 4.7

Engine low idle

24

Engine high idle

2.5 3.5

Engine low idle

46

2.5 3.5

Engine low idle

46

Engine high idle

2.5 3.5

Engine low idle

24

Engine high idle

2.5 3.5

Engine low idle

6 10

15

Engine high idle

2.8 3.8

Blade RAISE

Work equipment speed

Blade tilt (left and right tilt)


[Single tilt model]

Blade tilt (left and right tilt)


[Dual tilt model, Dual setting]

Engine high idle


sec

Blade dump
[Dual tilt specification]

Blade tilt (left and right tilt)


[Dual tilt model, Single setting]

Ripper tilt (ino out)

D375A-6
(03)

30-187
30-197

Pm Clinic
Pm Clinic service

Pm Clinic check sheet


Work order No.

D375A-6

Date of inspection
/

Hydraulic drift

Item

Blade lift cylinder

Visual inspection of
final drive drain plug
Visual check of final
drive drain plug

Service meter

Serviceman

Test conditions

Unit

Engine stopped
Hydraulic oil temperature:

Standard
value for
new
machine

Service
limit value

Max. 65

Max. 25

Standard
value for
new
machine

Service
limit value

Test
results

OK NG Remarks

Test
results

OK NG Remarks

mm/5min.
45 to 55 C

Ripper lift cylinder

Item

Serial No.

Test conditions

Unit

Engine speed

Engine stopped

There must be no excessive metal particles

Always fill in the record when repairing, adjusting, or replacing main parts.
Date

30-188

Service meter

Repair record

Date

Service meter

Repair record

D375A-6
(06)

DRAFT
Pm Clinic service
Pm Clinic service

D375A-6
(01)

30-189

DRAFT
Pm Clinic service
Pm Clinic service

30-190

D375A-6
(01)

DRAFT
Pm Clinic service
Pm Clinic service

D375A-6
(01)

30-191

DRAFT
Pm Clinic service
Pm Clinic service

30-192

D375A-6
(01)

DRAFT

D375A-6
SEN01868-02

BULLDOZER
D375A-6
Shop Manual

Machine model
D375A-6

Serial number
60001 and up

40 Troubleshooting

D375A-6
(01)

40-1

DRAFT
Contents

Contents
40 Troubleshooting
General Information on troubleshooting ...........................................................................................................
Points to remember when troubleshooting ...................................................................................................
Sequence of events in troubleshooting.........................................................................................................
Checks before troubleshooting .....................................................................................................................
Classification and procedures for troubleshooting ........................................................................................
Failure codes table........................................................................................................................................
Phenomena and troubleshooting numbers ...................................................................................................
Information in troubleshooting table..............................................................................................................
Troubleshooting method for disconnecting wiring harness of pressure sensor system................................
Connection table for connector pin numbers ................................................................................................
Connectors table and arrangement drawing.................................................................................................
T-branch box and T-branch adapter table ....................................................................................................
Fuse locations table ......................................................................................................................................
Troubleshooting by failure code .......................................................................................................................
Failure code [1380MW] Lock up clutch: Slip.................................................................................................
Failure code [1500L0] Transmission clutch: Abnormal .................................................................................
Failure code [15E0MW] Transmission clutch: Slip........................................................................................
Failure code [15SAL1] Forward clutch: Fill high ...........................................................................................
Failure code [15SALH] Forward clutch: Fill Low ...........................................................................................
Failure code [15SBL1] Reverse clutch: Fill high ...........................................................................................
Failure code [15SBLH] Reverse clutch: Fill Low...........................................................................................
Failure code [15SEL1] Speed 1st clutch: Fill high ........................................................................................
Failure code [15SELH] Speed 1st clutch: Fill Low ........................................................................................
Failure code [15SFL1] Speed 2nd clutch: Fill high .......................................................................................
Failure code [15SFLH] Speed 2nd clutch: Fill Low .......................................................................................
Failure code [15SGL1] Speed 3rd clutch: Fill high........................................................................................
Failure code [15SGLH] Speed 3rd clutch: Fill Low .......................................................................................
Failure code [15SJL1] L/U: Fill high ..............................................................................................................
Failure code [15SJLH] L/U: Fill low...............................................................................................................
Failure code [1800MW] P/T clutch: Slip........................................................................................................
Failure code [2201L1] Right clutch: Fill high .................................................................................................
Failure code [2201LH] Right clutch: Fill low..................................................................................................
Failure code [2202L1] Left clutch: Fill high ...................................................................................................
Failure code [2202LH] Left clutch: Fill low ....................................................................................................
Failure code [2300NR] Brake Themal Load Abnormality..............................................................................
Failure code [2301L1] Right brake: Fill high .................................................................................................
Failure code [2301LH] Right brake: Fill low ..................................................................................................
Failure code [2301NR] Steering Brake RH Themal Load Abnormality .........................................................
Failure code [2302L1] Left brake: Fill high....................................................................................................
Failure code [2302LH] Left brake: Fill low.....................................................................................................
Failure code [2302NR] Steering Brake LH Themal Load Abnormality..........................................................
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection..................................................................
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit .....................................................................
Failure code [AA10NX] Air Cleaner Clogging ...............................................................................................
Failure code [AB00MA] Battery Charge Abnormal .......................................................................................
Failure code [B@BAZG] Eng Oil Press Low.................................................................................................
Failure code [B@BAZK] Eng Oil Level Low..................................................................................................
Failure code [B@BCNS] Eng Water Overheat .............................................................................................
Failure code [B@BCZK] Eng Water Level Low ............................................................................................
Failure code [B@CENS] T/C Oil Overheat ...................................................................................................
Failure code [B@HANS] Hyd Oil Overheat...................................................................................................
Failure code [B@HAZK] Hyd Oil Level Low..................................................................................................
Failure code [CA111] ECM Critical Internal Failure ......................................................................................
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .........................................................................
Failure code [CA122] Chg Air Press Sensor High Error ...............................................................................

40-2

40 - 9
40 - 9
40 - 10
40 - 11
40 - 36
40 - 39
40 - 45
40 - 47
40 - 49
40 - 52
40 - 88
40 -102
40 -105
40 -109
40 -109
40 -110
40 -111
40 -112
40 -114
40 -116
40 -118
40 -120
40 -122
40 -124
40 -126
40 -128
40 -130
40 -132
40 -134
40 -136
40 -138
40 -140
40 -142
40 -144
40 -146
40 -148
40 -150
40 -152
40 -154
40 -156
40 -158
40 -160
40 -162
40 -164
40 -166
40 -166
40 -167
40 -168
40 -169
40 -170
40 -171
40 -172
40 -174
40 -176
40 -178

D375A-6
(01)

DRAFT
Contents

Failure code [CA123] Chg Air Press Sensor Low Error ................................................................................
Failure code [CA131] Throttle Sensor High Error .........................................................................................
Failure code [CA132] Throttle Sensor Low Error ..........................................................................................
Failure code [CA135] Eng Oil Press Sensor High Error ...............................................................................
Failure code [CA141] Eng Oil Press Sensor Low Error ................................................................................
Failure code [CA144] Coolant Temp Sens High Error ..................................................................................
Failure code [CA145] Coolant Temp Sens Low Error...................................................................................
Failure code [CA153] Chg Air Temp Sensor High Error ...............................................................................
Failure code [CA154] Chg Air Temp Sensor Low Error ................................................................................
Failure code [CA187] Sens Supply 2 Volt Low Error ....................................................................................
Failure code [CA212] Eng Oil Temp Sensor High Error ...............................................................................
Failure code [CA213] Eng Oil Temp Sensor Low Error ................................................................................
Failure code [CA221] Ambient Press Sens High Error .................................................................................
Failure code [CA222] Ambient Press Sens Low Error ..................................................................................
Failure code [CA227] Sens Supply 2 Volt High Error ...................................................................................
Failure code [CA234] Eng Overspeed ..........................................................................................................
Failure code [CA238] Ne Speed Sens Supply Volt Error..............................................................................
Failure code [CA263] Fuel Temp Sensor High Error ....................................................................................
Failure code [CA265] Fuel Temp Sensor Low Error .....................................................................................
Failure code [CA271] IMV/PCV1 Short Error................................................................................................
Failure code [CA272] IMV/PCV1 Open Error................................................................................................
Failure code [CA273] PCV2 Short Error .......................................................................................................
Failure code [CA274] PCV2 Open Error .......................................................................................................
Failure code [CA322] Inj #1 (L#1) Open/Short Error.....................................................................................
Failure code [CA323] Inj #5 (L#5) Open/Short Error.....................................................................................
Failure code [CA324] Inj #3 (L#3) Open/Short Error.....................................................................................
Failure code [CA325] Inj #6 (L#6) Open/Short Error.....................................................................................
Failure code [CA331] Inj #2 (L#2) Open/Short Error.....................................................................................
Failure code [CA332] Inj #4 (L#4) Open/Short Error.....................................................................................
Failure code [CA342] Calibration Code Incompatibility.................................................................................
Failure code [CA351] Injectors Drive Circuit Error ........................................................................................
Failure code [CA352] Sens Supply 1 Volt Low Error ....................................................................................
Failure code [CA386] Sens Supply 1 Volt High Error ...................................................................................
Failure code [CA441] Battery Voltage Low Error ..........................................................................................
Failure code [CA442] Battery Voltage High Error .........................................................................................
Failure code [CA449] Rail Press Very High Error .........................................................................................
Failure code [CA451] Rail Press Sensor High Error .....................................................................................
Failure code [CA452] Rail Press Sensor Low Error......................................................................................
Failure code [CA553] Rail Press High Error .................................................................................................
Failure code [CA554] Rail Press Sensor In Range Error..............................................................................
Failure code [CA559] Rail Press Low Error ..................................................................................................
Failure code [CA689] Eng Ne Speed Sensor Error ......................................................................................
Failure code [CA731] Eng Bkup Speed Sens Phase Error...........................................................................
Failure code [CA757] All Continuous Data Lost Error...................................................................................
Failure code [CA778] Eng Bkup Speed Sensor Error...................................................................................
Failure code [CA1228] EGR Valve Servo Error 1 .........................................................................................
Failure code [CA1625] EGR Valve Servo Error 2 .........................................................................................
Failure code [CA1633] KOMNET Datalink Timeout Error.............................................................................
Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................
Failure code [CA2186] Throt Sens Sup Volt Low Error ................................................................................
Failure code [CA2249] Rail Press Very Low Error........................................................................................
Failure code [CA2271] EGR Valve Pos Sens High Error..............................................................................
Failure code [CA2272] EGR Valve Pos Sens Low Error ..............................................................................
Failure code [CA2351] EGR Valve Sol Current High Error...........................................................................
Failure code [CA2352] EGR Valve Sol Current Low Error............................................................................
Failure code [D110KB] Battery Relay: Drive Short Circuit ............................................................................
Failure code [D130KA] Neutral relay: Disconnection....................................................................................
Failure code [D130KB] Neutral relay: Short circuit .......................................................................................

D375A-6
(01)

40 -180
40 -182
40 -184
40 -186
40 -188
40 -190
40 -192
40 -194
40 -196
40 -198
40 -200
40 -202
40 -204
40 -206
40 -208
40 -209
40 -210
40 -212
40 -214
40 -216
40 -217
40 -218
40 -219
40 -220
40 -222
40 -224
40 -226
40 -228
40 -230
40 -232
40 -233
40 -234
40 -236
40 -237
40 -238
40 -239
40 -240
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40 -244
40 -245
40 -246
40 -250
40 -252
40 -253
40 -254
40 -256
40 -257
40 -258
40 -259
40 -260
40 -261
40 -262
40 -264
40 -266
40 -268
40 -270
40 -272
40 -274

40-3

DRAFT
Contents

Failure code [D161KA] Back-up alarm releay: Disconnection ......................................................................


Failure code [D161KB] Back-up alarm releay: Short circuit..........................................................................
Failure code [D182KZ] Preheater Relay Abnormality ...................................................................................
Failure code [D190KA] ACC signal relay: Disconnection .............................................................................
Failure code [D190KB] ACC signal relay: Short circuit .................................................................................
Failure code [D1EFKA] Pre lub. motor relay: Disconnection ........................................................................
Failure code [D1EFKB] Pre lub. motor relay: Short circuit............................................................................
Failure code [DAFRKR] Monitor: Can communication lost (PT) ...................................................................
Failure code [dAFRKR] Monitor: CAN communication lost (WE) .................................................................
Failure code [DAFRMC] CAN Discon (Monitor Detected) ............................................................................
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)...............................................................
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) ......................................................
Failure code [DB90KT] WE controller: Abnormality in controller ..................................................................
Failure code [DB91KK] WE controller: Source voltage reduction .................................................................
Failure code [DB92KK] WE controller: Output voltage reduction..................................................................
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ............................................................
Failure code [DB99KQ] WE controller: Type select signal............................................................................
Failure code [DB9RKR] WE controller: Can communication lost (PT)..........................................................
Failure code [DBB0KK] VHMS controller:Source voltage reduction .............................................................
Failure code [DBB0KQ] VHMS connector connection abnormality ..............................................................
Failure code [DBB3KK] VHMS controller: Source voltage reduction ............................................................
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction...............................................................
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction................................................................
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction................................................................
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) ...........................................................
Failure code [DBE0KT] PT controller: Abnormality in controller ...................................................................
Failure code [DBE1KK] PT controller: Source voltage reduction..................................................................
Failure code [DBE2KK] PT controller: Output voltage reduction ..................................................................
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction .............................................................
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction ................................................................
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction .............................................................
Failure code [DBE9KQ] PT controller: Type select signal ............................................................................
Failure code [DBERKR] PT controller: Can communication lost (WE) .........................................................
Failure code [DD12KA] Shift up Sw: Disconnection .....................................................................................
Failure code [DD12KB] Shift up Sw: Short circuit .........................................................................................
Failure code [DD13KA] Shift down Sw: Disconnection.................................................................................
Failure code [DD13KB] Shift down Sw: Short circuit ....................................................................................
Failure code [DD14KA] Parking lever Sw: Dissconnection...........................................................................
Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................
Failure code [DDB9L4] Reverse SW Signal disagreement...........................................................................
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection .......................................................................
Failure code [DDK3L4] Forward SW Signal disagreement...........................................................................
Failure code [DDK5KA] Shift switch disconnection.......................................................................................
Failure code [DDK5KB] Shift switch short circuit ..........................................................................................
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality ..................................................................
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality ...................................................................
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ...................................................................
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit.......................................................................
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection........................................................................
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit ...........................................................................
Failure code [DDNALD] Blade lift up pressure SW abnormality ...................................................................
Failure code [DDNBLD] Ripper lift up pressure SW abnormality..................................................................
Failure code [DDNCLD] Ripper lift down pressure SW abnormality .............................................................
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality ...................................................................
Failure code [DDNELD] Ripper tilt back pressure SW abnormality ..............................................................
Failure code [DDNFLD] Blade lift down pressure SW abnormality ...............................................................
Failure code [DDNLKA] Weq lock Sw: Disconnection ..................................................................................
Failure code [DDNLKB] Weq lock Sw: Short circuit......................................................................................

40-4

40 -276
40 -278
40 -280
40 -282
40 -284
40 -286
40 -288
40 -290
40 -291
40 -292
40 -297
40 -300
40 -301
40 -302
40 -304
40 -306
40 -308
40 -309
40 -312
40 -314
40 -316
40 -318
40 -320
40 -322
40 -323
40 -323
40 -324
40 -326
40 -328
40 -330
40 -332
40 -334
40 -335
40 -338
40 -340
40 -342
40 -344
40 -346
40 -348
40 -350
40 -352
40 -354
40 -356
40 -358
40 -360
40 -362
40 -364
40 -366
40 -368
40 -370
40 -372
40 -374
40 -376
40 -378
40 -380
40 -382
40 -384
40 -386

D375A-6
(01)

DRAFT
Contents

Failure code [DDT5KA] Neutral switch disconnection ..................................................................................


Failure code [DDT5KB] Neutral switch short circuit ......................................................................................
Failure code [DDT5KQ] Lever SPEC selection signal disagreement ...........................................................
Failure code [DDTSL1] S/C: Fill high ............................................................................................................
Failure code [DDTSLH] S/C: Fill low.............................................................................................................
Failure code [DGE5KX] Ambient temp sensor abnormality ..........................................................................
Failure code [DGS1KX] Hyd oil temp: signal abnormal ................................................................................
Failure code [DGT1KA] T/C oil temp sensor: Abnormal ...............................................................................
Failure code [DGT1KX] T/C oil temp sensor: Abnormal ...............................................................................
Failure code [DGT5KA] F exhaust temp sensor disconnection ....................................................................
Failure code [DGT5KB] F exhaust temp sensor short circuit........................................................................
Failure code [DGT6KA] R exhaust temp sensor disconnection....................................................................
Failure code [DGT6KB] R exhaust temp sensor short circuit .......................................................................
Failure code [DH21KA] Weq pressure sensor: Disconnection .....................................................................
Failure code [DH21KB] Weq pressure sensor: Short circuit .........................................................................
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection.........................................................
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ............................................................
Failure code [DHT3KX] T/M oil pressure sensor abnormality.......................................................................
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection...................................................................
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ......................................................................
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection.................................................................
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ....................................................................
Failure code [DK10KA] Fuel control Dial: Disconnection..............................................................................
Failure code [DK10KB] Fuel control Dial: Short circuit .................................................................................
Failure code [DK30KA] ST lever 1: Disconnection .......................................................................................
Failure code [DK30KB] ST lever 1: Short circuit ...........................................................................................
Failure code [DK30KX] ST lever: Out of normal range .................................................................................
Failure code [DK30KZ] ST lever: Disconnection or short circuit ...................................................................
Failure code [DK30L8] ST lever: Signal mismatch .....................................................................