Bulldozer - 5E0: Serial Numbers and Up

SEN00986-11
BULLDOZER D375A -5E0

SERIAL NUMBERS 50001 and up
SEN00988-11
BULLDOZER 1SHOP MANUAL
D375A-5E0
Machine model Serial number

D375A-5E0 50001 and up
00 Index and foreword 1

Index
Composition of shop manual .......................................................................................................................... 2
Table of contents ............................................................................................................................................. 4
D375A-5E0 1
SEN00988-11 00 Index and foreword
Composition of shop manual 1

The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tub No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs SEN00986-11
00 Index and foreword SEN00987-11

Index SEN00988-11 q
Foreword and general information SEN00989-04
01 Specification SEN00990-01
Specification and technical data SEN00991-01
10 Structure, function and maintenance standard SEN00992-04

Engine and cooling system SEN00993-01
Power train, Part 1 SEN00994-01
Undercarriage and frame SEN00996-02
Hydraulic system, Part 1 SEN00997-01
Work equipment SEN00999-01
Cab and its attachments SEN01000-01
Electrical system SEN01001-03
20 Standard value table SEN01002-01

Standard service value table SEN01931-01
30 Testing and adjusting SEN01003-04

Testing and adjusting, Part 1 SEN01932-02
Testing and adjusting, Part 4 SEN01935-02 q
40 Troubleshooting SEN01004-02
Failure code table and fuse locations SEN01867-02
General information on troubleshooting SEN01868-02
Troubleshooting by failure code, Part 1 SEN01869-01
2 D375A-5E0

Troubleshooting of electrical system (E-mode) SEN01875-02
Troubleshooting of hydraulic, mechanical system (H-mode) SEN01876-01
Troubleshooting of engine (S-mode) SEN01877-01
50 Disassembly and assembly SEN01005-02

General information on disassembly and assembly SEN02362-02
Engine SEN02364-01
Undercarriage and frame, Part 1 SEN02367-01
Hydraulic system SEN02369-01
90 Diagrams and drawings SEN01006-04

Hydraulic diagrams and drawings SEN01007-02
Electrical diagrams and drawings SEN01008-03
D375A-5E0 3
Table of contents 1
00 Index and foreword
Index SEN00988-11
Composition of shop manual....................................................................................................... 2
Table of contents ......................................................................................................................... 4
Foreword and general information SEN00989-04

Safety notice................................................................................................................................ 2
How to read the shop manual ..................................................................................................... 7
Explanation of terms for maintenance standard.......................................................................... 9
Handling of electric equipment and hydraulic component........................................................... 11
Handling of connectors newly used for engines.......................................................................... 20
How to read electric wire code .................................................................................................... 23
Precautions when carrying out operation .................................................................................... 26
Method of disassembling and connecting push-pull type coupler ............................................... 29
Standard tightening torque table ................................................................................................. 32
Conversion table ......................................................................................................................... 36
01 Specification
Specification and technical data SEN00991-01
Specification drawing................................................................................................................... 2
Specifications .............................................................................................................................. 3
Weight table ................................................................................................................................ 8
Table of fuel, coolant and lubricants ............................................................................................ 10
10 Structure, function and maintenance standard

Engine mount .............................................................................................................................. 2
Cooling system............................................................................................................................ 4
Cooling fan pump ........................................................................................................................ 6
Cooling fan motor ........................................................................................................................ 22
Power train .................................................................................................................................. 2
Overall drawing of power train unit.............................................................................................. 4
Power train hydraulic piping drawing........................................................................................... 6
Damper, universal joint................................................................................................................ 8
Torque converter, PTO ................................................................................................................ 10
Scavenging pump........................................................................................................................ 17
Torque converter valve ................................................................................................................ 18
Transmission control ................................................................................................................... 2
Transmission ............................................................................................................................... 8
Transmission ECMV.................................................................................................................... 22
Transmission lubrication relief valve............................................................................................ 28
Power train pump + lubrication pump.......................................................................................... 29
Steering, brake control ................................................................................................................ 30
Transfer, bevel gear shaft, steering ............................................................................................. 32
Steering ECMV............................................................................................................................ 42
Steering clutch ECMV, Steering brake ECMV ............................................................................. 46
Parking brake valve..................................................................................................................... 53
Sudden stop prevention valve ..................................................................................................... 54
Final drive.................................................................................................................................... 55
Sprocket ...................................................................................................................................... 60
Undercarriage and frame SEN00996-02
Track frame ................................................................................................................................. 2
4 D375A-5E0
Recoil spring ............................................................................................................................... 4

Idler ............................................................................................................................................. 6
Track roller .................................................................................................................................. 8
Carrier roller ................................................................................................................................ 10
Track roller bogie......................................................................................................................... 11
Track shoe................................................................................................................................... 12
Main frame .................................................................................................................................. 16
Suspension ................................................................................................................................. 18
Work equipment hydraulic piping diagram .................................................................................. 2
PPC control piping diagram ........................................................................................................ 6
Work equipment control .............................................................................................................. 8
Hydraulic tank ............................................................................................................................. 10
Accumulator ................................................................................................................................ 12
PPC lock valve ............................................................................................................................ 13
PPC valve ................................................................................................................................... 14
Hydraulic cylinder........................................................................................................................ 28
Piston valve................................................................................................................................. 32
Quick drop valve ......................................................................................................................... 33
Pin puller switch .......................................................................................................................... 35
Pin puller solenoid valve ............................................................................................................. 36
Blade control knob (Only the machine with dual tilt) ................................................................... 38
Pitch, dual tilt solenoid valve ....................................................................................................... 39
Work equipment pump ................................................................................................................ 42
Control valve ............................................................................................................................... 2
Self pressure reducing valve....................................................................................................... 34
Cylinder stay ............................................................................................................................... 2
Blade ........................................................................................................................................... 4
Cutting edge, end bit ................................................................................................................... 8
Ripper.......................................................................................................................................... 10
Cab mount................................................................................................................................... 2
Cab.............................................................................................................................................. 3
Air conditioner ............................................................................................................................. 5
Engine control system................................................................................................................. 2
CRI engine control system .......................................................................................................... 12
Monitor system............................................................................................................................ 14
Machine monitor.......................................................................................................................... 16
Mode selection system................................................................................................................ 30
Electrical equipment.................................................................................................................... 34
Palm command control system ................................................................................................... 36
Sensors ....................................................................................................................................... 38
Vehicle health monitoring system (VHMS).................................................................................. 42
ORBCOMM terminal system ....................................................................................................... 48
20 Standard value table

Standard service value table SEN01931-01
Standard value table for engine .................................................................................................. 2
Standard value table for machine................................................................................................ 3
D375A-5E0 5
30 Testing and adjusting

Tools for testing, adjusting, and troubleshooting ......................................................................... 3
Testing engine speed .................................................................................................................. 6
Testing intake air pressure (boost pressure) ............................................................................... 9
Testing exhaust temperature ....................................................................................................... 11
Testing exhaust gas color............................................................................................................ 13
Adjusting valve clearance............................................................................................................ 15
Testing compression pressure..................................................................................................... 17
Testing blow-by pressure............................................................................................................. 20
Testing engine oil pressure.......................................................................................................... 21
Testing EGR valve and bypass valve drive oil pressure.............................................................. 22
Handling of fuel system devices.................................................................................................. 24
Releasing residual pressure from fuel system ............................................................................ 24
Testing fuel pressure ................................................................................................................... 25
Handling of reduced cylinder mode operation............................................................................. 26
Handling of no injection cranking operation ................................................................................ 26
Testing leakage from pressure limiter and return rate from injector ............................................ 27
Bleeding air from fuel circuit ........................................................................................................ 30
Testing fuel circuit for leakage ..................................................................................................... 32
Handling controller voltage circuit ............................................................................................... 33
Replacing and adjusting alternator and air conditioner compressor belt..................................... 33
Testing fan motor speed .............................................................................................................. 34
Testing fan circuit oil pressure ..................................................................................................... 36
Bleeding air from fan pump ......................................................................................................... 37
Adjusting fuel control dial and decelerator pedal......................................................................... 38
Testing power train oil pressure................................................................................................... 3
Adjusting transmission speed sensor.......................................................................................... 13
Simple procedure for testing brake performance ........................................................................ 14
Adjusting brake pedal and parking brake lever ........................................................................... 16
Adjusting position of pccs lever console...................................................................................... 19
Emergency escape method when there is failure in power train................................................. 20
Inspecting wear of sprocket......................................................................................................... 22
Testing and adjusting track shoe tension .................................................................................... 23
Testing work equipment oil pressure ........................................................................................... 24
Testing control circuit main pressure ........................................................................................... 27
Testing PPC valve output pressure ............................................................................................. 28
Adjusting play of PPC valve ........................................................................................................ 30
Testing output pressure of ripper pin-puller solenoid valve ......................................................... 31
Checking location of cause of hydraulic drift of blade and ripper ................................................ 32
Testing leakage inside work equipment cylinder ......................................................................... 33
Releasing remaining pressure in work equipment cylinders ....................................................... 34
Bleeding air from work equipment cylinders................................................................................ 34
Adjusting ripper lever position ..................................................................................................... 35
Adjusting work equipment lock lever ........................................................................................... 36
Testing and adjusting operator's cab ........................................................................................... 37
Adjusting blade............................................................................................................................ 41
Special functions of monitor panel (EMMS) ................................................................................ 2
Adjustment method when controller has been replaced ............................................................. 2
Preparation work for troubleshooting for electrical equipment system ........................................ 4
Inspection procedure of diode ..................................................................................................... 7
Handling of optional devices ....................................................................................................... 8
Request for opening ORBCOMM terminal .................................................................................. 9
Initialization procedures for VHMS controller .............................................................................. 11
6 D375A-5E0
Using method of KOMTRAX functions of ORBCOMM terminal .................................................. 33

Precautions for replacing VHMS controller ................................................................................. 36
Pm Clinic service......................................................................................................................... 42
40 Troubleshooting
Failure code table and fuse locations SEN01867-02
Failure codes table ...................................................................................................................... 2
Fuse locations ............................................................................................................................. 12
General information on troubleshooting SEN01868-02
Points to remember when troubleshooting.................................................................................. 2
Sequence of events in troubleshooting ....................................................................................... 3
Check before troubleshooting ..................................................................................................... 4
Classification and procedures for troubleshooting ...................................................................... 5
Information in troubleshooting table ............................................................................................ 8
Connection table for connector pin numbers .............................................................................. 10
T-branch box and T-branch adapter table ................................................................................... 46
Failure code [1380MW] Lockup clutch slip.................................................................................. 3
Failure code [1500L0] Transmission clutch dual engagement .................................................... 4
Failure code [15E0MW] Transmission clutch slip........................................................................ 5
Failure code [15SAL1] When forward clutch oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 6
Failure code [15SALH] When forward clutch oil pressure command current is ON, 
fill signal is OFF ................................................................................................................... 8
Failure code [15SBL1] When reverse clutch oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 10
Failure code [15SBLH] When reverse clutch oil pressure command current is ON, 
Failure code [15SEL1] When 1st clutch oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 14
Failure code [15SELH] When 1st clutch oil pressure command current is ON, 
Failure code [15SFL1] When 2nd clutch oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 18
Failure code [15SFLH] When 2nd clutch oil pressure command current is ON, 
Failure code [15SGL1] When 3rd clutch oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 22
Failure code [15SGLH] When 3rd clutch oil pressure command current is ON, 
Failure code [1800MW] Power train clutch slip ........................................................................... 26
Failure code [2201L1] When right steering clutch oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 28
Failure code [2201LH] When right steering clutch oil pressure command current is ON, 
Failure code [2202L1] When left steering clutch oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 32
Failure code [2202LH] When left steering clutch oil pressure command current is ON, 
Failure code [2300NR] Brake thermal load abnormality ............................................................. 36
Failure code [2301L1] When right steering brake oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 38
Failure code [2301LH] When right steering brake oil pressure command current is ON, 
Failure code [2301NR] Right steering brake thermal load abnormality....................................... 42
Failure code [2302L1] When left steering brake oil pressure command current is OFF, 
fill signal is ON ..................................................................................................................... 44
D375A-5E0 7
Failure code [2302LH] When left steering brake oil pressure command current is ON, 
fill signal is OFF.................................................................................................................... 46
Failure code [2302NR] Left steering brake thermal load abnormality ......................................... 48
Failure code [6001ZK] Failure code for design ........................................................................... 48
Failure code [A000NS] Engine overheat ..................................................................................... 49
Failure code [AA10NX] Air cleaner clogging ............................................................................... 50
Failure code [AB00MA] Alternator malfunction ........................................................................... 51
Failure code [B@BAZG] Engine oil pressure low........................................................................ 52
Failure code [B@BAZK] Engine oil level reduction ..................................................................... 53
Failure code [B@BCNS] Engine coolant overheat...................................................................... 54
Failure code [B@BCZK] Radiator coolant level reduction........................................................... 55
Failure code [B@BEBF] Water in engine fuel ............................................................................. 56
Failure code [B@BFZK] Fuel level reduction .............................................................................. 57
Failure code [B@CENS] Power train oil overheat....................................................................... 58
Failure code [B@CHZG] HSS charge oil pressure reduction...................................................... 59
Failure code [B@CHZK] Power train oil level reduction.............................................................. 59
Failure code [B@GAZK] Battery electrolyte level reduction........................................................ 60
Failure code [B@HANS] Hydraulic oil overheat .......................................................................... 60
Failure code [B@HAZK] Hydraulic oil level reduction ................................................................. 61
Failure code [CA111] Engine controller internal abnormality....................................................... 4
Failure code [CA115] Engine Ne/Bkup speed sensor abnormality.............................................. 6
Failure code [CA122] Charge pressure sensor abnormally high level ........................................ 8
Failure code [CA123] Charge pressure sensor abnormally low level.......................................... 10
Failure code [CA131] Throttle sensor abnormally high level....................................................... 12
Failure code [CA132] Throttle sensor abnormally low level ........................................................ 14
Failure code [CA135] Engine oil pressure sensor abnormally high level .................................... 16
Failure code [CA141] Engine oil pressure sensor abnormally low level...................................... 18
Failure code [CA144] Coolant temperature sensor abnormally high level .................................. 20
Failure code [CA145] Coolant temperature sensor abnormally low level.................................... 22
Failure code [CA153] Charge temperature sensor abnormally high level................................... 24
Failure code [CA154] Charge temperature sensor abnormally low level .................................... 26
Failure code [CA187] Sensor power supply 2 abnormally low level............................................ 27
Failure code [CA212] Engine oil temperature sensor abnormally high level............................... 28
Failure code [CA213] Engine oil temperature sensor abnormally low level ................................ 30
Failure code [CA221] Ambient temperature sensor abnormally high level ................................. 32
Failure code [CA222] Ambient temperature sensor abnormally low level................................... 34
Failure code [CA227] Sensor power supply 2 abnormally high level .......................................... 36
Failure code [CA234] Engine overspeed..................................................................................... 38
Failure code [CA238] Ne speed sensor power supply abnormality............................................. 40
Failure code [CA263] Fuel temperature sensor abnormally high level........................................ 42
Failure code [CA265] Fuel temperature sensor abnormally low level ......................................... 44
Failure code [CA271] PCV1 short circuit..................................................................................... 46
Failure code [CA272] PCV1 disconnection ................................................................................. 48
Failure code [CA273] PCV2 short circuit..................................................................................... 50
Failure code [CA274] PCV2 disconnection ................................................................................. 52
Failure code [CA322] Injector #1 system disconnection or short circuit...................................... 54
Failure code [CA342] Engine controller data mismatch .............................................................. 66
Failure code [CA351] Injector drive circuit abnormality ............................................................... 68
Failure code [CA352] Sensor power supply 1 abnormally low level............................................ 70
Failure code [CA386] Sensor power supply 1 abnormally high level .......................................... 72
Failure code [CA441] Power supply voltage abnormally low level .............................................. 74
Failure code [CA442] Power supply voltage abnormally high level............................................. 74
8 D375A-5E0
Failure code [CA449] Common rail pressure abnormally high pressure 2.................................. 75
Failure code [CA451] Common rail pressure sensor abnormally high level ............................... 76
Failure code [CA452] Common rail pressure sensor abnormally low level ................................. 78
Failure code [CA553] Common rail pressure abnormally high pressure 1.................................. 79
Failure code [CA554] Common rail pressure sensor in-range abnormality ................................ 80
Failure code [CA559] Supply pump low pressure 1 .................................................................... 81
Failure code [CA689] Engine Ne speed sensor abnormality ...................................................... 86
Failure code [CA731] Engine Bkup speed sensor phase abnormality ........................................ 88
Failure code [CA757] Engine controller all data loss .................................................................. 89
Failure code [CA778] Engine Bkup speed sensor abnormality................................................... 90
Failure code [CA1228] EGR valve servo abnormality 1.............................................................. 3
Failure code [CA1625] EGR valve servo abnormality 2.............................................................. 4
Failure code [CA1633] CAN communication error (Engine controller)........................................ 6
Failure code [CA2185] Throttle sensor power supply abnormally high level .............................. 8
Failure code [CA2186] Throttle sensor power supply abnormally low level ................................ 10
Failure code [CA2249] Supply pump low pressure 2 .................................................................. 11
Failure code [CA2271] EGR valve lift sensor abnormally high level ........................................... 12
Failure code [CA2272] EGR valve lift sensor abnormally low level ............................................ 14
Failure code [CA2351] EGR valve solenoid drive short circuit.................................................... 16
Failure code [CA2352] EGR valve solenoid drive disconnection ................................................ 18
Failure code [D110KA] Battery relay hold line disconnection...................................................... 20
Failure code [D110KB] Battery relay hold line short circuit ......................................................... 22
Failure code [D130KA] Neutral safety relay disconnection ......................................................... 24
Failure code [D130KB] Neutral safety relay short circuit............................................................. 26
Failure code [D161KA] Backup alarm relay disconnection ......................................................... 28
Failure code [D161KB] Backup alarm relay short circuit ............................................................. 30
Failure code [D182KZ] Preheater relay disconnection or short circuit ........................................ 32
Failure code [D190KA] Engine controller ACC signal cut relay disconnection ........................... 34
Failure code [D190KB] Engine controller ACC signal cut relay short circuit ............................... 36
Failure code [D5ZRKA] Snap shot switch disconnection ............................................................ 38
Failure code [D5ZRKB] Snap shot switch short circuit................................................................ 39
Failure code [DAFRKR] Machine monitor CAN communication error......................................... 40
Failure code [daFRKR] Machine monitor CAN communication error.......................................... 42
Failure code [dAFRKR] Machine monitor CAN communication error ......................................... 44
Failure code [DAQ0KT] Transmission controller internal abnormality......................................... 46
Failure code [DAQ1KK] Transmission controller main power supply voltage reduction ............. 48
Failure code [DAQ2KK] Transmission controller load power supply voltage reduction .............. 50
Failure code [DAQ5KK] Transmission controller sensor 5V power supply (1) 
voltage reduction.................................................................................................................. 52
Failure code [DAQ6KK] Transmission controller sensor 24V power supply voltage reduction ... 54
Failure code [DAQ7KK] Transmission controller sensor 5V power supply (2) 
voltage reduction.................................................................................................................. 56
Failure code [DAQ9KQ] Transmission controller model selection signal disagreement ............. 58
Failure code [DAQRKR] Transmission controller CAN communication error.............................. 60
Failure code [DAQSKR] Transmission controller S-NET communication error........................... 62
Failure code [DB2RKR] Engine controller CAN communication error ........................................ 4
Failure code [dB2RKR] Engine controller CAN communication error ......................................... 6
Failure code [DB30KT] Steering controller internal abnormality ................................................. 8
Failure code [DB31KK] Steering controller main power supply voltage reduction ...................... 10
Failure code [DB32KK] Steering controller load power supply voltage reduction ....................... 12
Failure code [DB35KK] Steering controller sensor 5V power supply (1) voltage reduction ........ 14
Failure code [DB36KK] Steering controller sensor 24V power supply voltage reduction ............ 16
Failure code [DB37KK] Steering controller sensor 5V power supply (2) voltage reduction ........ 18
Failure code [DB39KQ] Steering controller model selection signal disagreement ...................... 20
Failure code [dB3RKR] Steering controller CAN communication error ....................................... 22
D375A-5E0 9
Failure code [DB3SKR] Steering controller S-NET communication error.................................... 24

Failure code [DBB0KK] (or VHMS LED display "n901") VHMS supply voltage abnormality....... 26
Failure code [DBB0KQ] (or VHMS LED display "nF11") VHMS connector connection 
abnormality........................................................................................................................... 28
Failure code [DBB3KK] (or VHMS LED display "n905") VHMS controller battery direct 
power supply voltage reduction............................................................................................ 30
Failure code [DBB5KP] (or VHMS LED display "n904") Sensor power supply (5V) system 
abnormality........................................................................................................................... 32
disconnection or short circuit................................................................................................ 34
Failure code [DBBQKR] (or VHMS LED display "n802") CAN communication error 
(VHMS controller)................................................................................................................. 38
Failure code [dbBRKR] VHMS controller CAN communication error .......................................... 42
Failure code [DD12KA] Shift-up switch disconnection ................................................................ 44
Failure code [DD12KB] Shift-up switch short circuit .................................................................... 46
Failure code [DD13KA] Shift-down switch disconnection............................................................ 48
Failure code [DD13KB] Shift-down switch short circuit ............................................................... 50
Failure code [DD14KA] Parking brake lever switch disconnection.............................................. 52
Failure code [DD14KB] Parking brake lever switch short circuit ................................................. 54
Failure code [DDB9L4] Reverse switch disagreement................................................................ 56
Failure code [DDK3L4] Forward switch signal disagreement...................................................... 58
Failure code [DDK5KA] Shift switch disconnection ..................................................................... 4
Failure code [DDK5KB] Shift switch short circuit......................................................................... 6
Failure code [DDN2LD] Blade tilt right oil pressure switch is held down for long time ................ 8
Failure code [DDN3LD] Blade tilt left oil pressure switch is held down for long time .................. 10
Failure code [DDN7KA] Blade pitch switch disconnection .......................................................... 12
Failure code [DDN7KB] Blade pitch switch short circuit.............................................................. 14
Failure code [DDN9KA] Blade tilt switch disconnection .............................................................. 16
Failure code [DDN9KB] Blade tilt switch short circuit.................................................................. 18
Failure code [DDNALD] Blade lift raise oil pressure switch is held down for long time ............... 20
Failure code [DDNBLD] Ripper lift raise oil pressure switch is held down for long time ............. 22
Failure code [DDNCLD] Ripper lift lower oil pressure switch is held down for long time ............ 24
Failure code [DDNDLD] Ripper tilt in oil pressure switch is held down for long time .................. 26
Failure code [DDNELD] Ripper tilt back oil pressure switch is held down for long time.............. 28
Failure code [DDNFLD] Blade lift lower oil pressure switch is held down for long time .............. 30
Failure code [DDQ2KA] Parking brake lever switch disconnection............................................. 32
Failure code [DDQ2KB] Parking brake lever switch short circuit ................................................ 34
Failure code [DDQ2L4] Parking brake lever switch ON/OFF signal disagreement..................... 36
Failure code [dDQ2L4] Parking brake lever switch ON/OFF signal disagreement ..................... 37
Failure code [DDT5KA] Neutral switch disconnection................................................................. 38
Failure code [DDT5KB] Neutral switch short circuit .................................................................... 40
Failure code [DDT5KQ] Lever specification selection signal disagreement................................ 42
Failure code [DGE5KX] (or VHMS LED display "n40") Ambient temperature sensor system 
Failure code [DGS1KX] Hydraulic oil temperature sensor signal out of range............................ 46
Failure code [DGT1KA] Power train oil temperature sensor disconnection ................................ 48
Failure code [DGT1KX] Power train oil temperature sensor input signal out of range................ 50
Failure code [DGT5KA] (or VHMS LED display "n322") Front exhaust temperature sensor 
system short circuit .............................................................................................................. 52
Failure code [DGT5KB] (or VHMS LED display "n321") Front exhaust temperature sensor 
system disconnection........................................................................................................... 54
Failure code [DGT6KA] (or VHMS LED display "n312") Rear exhaust temperature sensor 
Failure code [DGT6KB] (or VHMS LED display "n311") Rear exhaust temperature sensor 
10 D375A-5E0
Failure code [DH22KA] Work equipment pump oil pressure sensor 1 disconnection ................. 60
Failure code [DH22KB] Work equipment pump oil pressure sensor 1 short circuit..................... 62
Failure code [DH23KA] Work equipment pump oil pressure sensor 2 disconnection ................. 64
Failure code [DH23KB] Work equipment pump oil pressure sensor 2 short circuit..................... 66
Failure code [DHE5KB] (or VHMS LED display "n332") Engine blow-by pressure sensor 
Failure code [DHE5KY] (or VHMS LED display "n331") Engine blow-by pressure sensor 
Failure code [DHT3KX] (or VHMS LED display "n614") Transmission oil pressure sensor 
input signal out of range....................................................................................................... 72
Failure code [DK10KA] Fuel control dial disconnection .............................................................. 74
Failure code [DK10KB] Fuel control dial short circuit.................................................................. 76
Failure code [DK30KA] Steering potentiometer 1 disconnection ................................................ 4
Failure code [DK30KB] Steering potentiometer 1 short circuit .................................................... 6
Failure code [DK30KX] Steering potentiometer 1 input signal out of range ................................ 8
Failure code [DK30KZ] Steering potentiometer 1 disconnection or short circuit ......................... 9
Failure code [DK30L8] Steering potentiometer 1 analog signal disagreement ........................... 10
Failure code [DK31KA] Steering potentiometer 2 disconnection ................................................ 12
Failure code [DK31KB] Steering potentiometer 2 short circuit .................................................... 14
Failure code [DK40KA] Brake potentiometer disconnection ....................................................... 16
Failure code [DK40KB] Brake potentiometer short circuit........................................................... 18
Failure code [DK55KX] Direction potentiometer input signal out of range .................................. 20
Failure code [DK55KZ] Direction potentiometer disconnection or short circuit ........................... 21
Failure code [DK55L8] Direction potentiometer analog signal disagreement ............................. 22
Failure code [DK56KA] Direction potentiometer 1 disconnection ............................................... 24
Failure code [DK56KB] Direction potentiometer 1 short circuit ................................................... 26
Failure code [DK57KA] Direction potentiometer 2 disconnection ............................................... 28
Failure code [DK57KB] Direction potentiometer 2 short circuit ................................................... 30
Failure code [DK60KA] Acceleration sensor disconnection ........................................................ 32
Failure code [DK60KB] Acceleration sensor short circuit............................................................ 34
Failure code [DKH1KA] Pitch angle sensor disconnection ......................................................... 36
Failure code [DKH1KB] Pitch angle sensor short circuit ............................................................. 38
Failure code [DKH1KX] Pitch angle sensor input signal out of range ......................................... 39
Failure code [DLF1KA] Torque converter output speed sensor disconnection ........................... 40
Failure code [DLT3KA] Transmission output speed sensor disconnection 1 .............................. 41
Failure code [dLT3KA] Transmission output speed sensor disconnection 2 ............................... 42
Failure code [DLT3KB] Transmission output speed sensor short circuit ..................................... 43
Failure code [DV00KB] Alarm buzzer short circuit ...................................................................... 44
Failure code [DW59KA] Blade dual selector solenoid disconnection.......................................... 45
Failure code [DW59KB] Blade dual selector solenoid short circuit ............................................. 46
Failure code [DW59KY] Blade dual selector solenoid hot short.................................................. 47
Failure code [DW5AKA] Blade pitch selector solenoid disconnection ........................................ 48
Failure code [DW5AKB] Blade pitch selector solenoid short circuit ............................................ 49
Failure code [DW5AKY] Blade pitch selector solenoid hot short ................................................ 50
Failure code [DW7BKA] Fan reverse solenoid disconnection..................................................... 51
Failure code [DW7BKB] Fan reverse solenoid short circuit ........................................................ 52
Failure code [DW7BKY] Fan reverse solenoid hot short............................................................. 53
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection.................................. 54
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit ..................................... 56
Failure code [DWN3KY] Sudden stop prevention solenoid hot short.......................................... 58
Failure code [DWN5KA] Fan pulley solenoid 1 disconnection .................................................... 60
Failure code [DWN5KB] Fan pulley solenoid 1 short circuit........................................................ 62
Failure code [DWN5KY] Fan pulley solenoid 1 hot short ............................................................ 64
Failure code [DWNCKA] Fan pulley solenoid 2 disconnection ................................................... 66
Failure code [DWNCKB] Fan pulley solenoid 2 short circuit ....................................................... 68
Failure code [DWNCKY] Fan pulley solenoid 2 hot short ........................................................... 70
D375A-5E0 11
Failure code [DXH1KA] Lockup solenoid disconnection ............................................................. 4

Failure code [DXH1KB] Lockup solenoid short circuit................................................................. 6
Failure code [DXH1KY] Lockup solenoid hot short ..................................................................... 8
Failure code [DXH4KA] 1st clutch ECMV disconnection............................................................. 10
Failure code [DXH4KB] 1st clutch ECMV short circuit ................................................................ 12
Failure code [DXH4KY] 1st clutch ECMV hot short..................................................................... 14
Failure code [DXH5KA] 2nd clutch ECMV disconnection ........................................................... 16
Failure code [DXH5KB] 2nd clutch ECMV short circuit ............................................................... 18
Failure code [DXH5KY] 2nd clutch ECMV hot short ................................................................... 20
Failure code [DXH6KA] 3rd clutch ECMV disconnection ............................................................ 22
Failure code [DXH6KB] 3rd clutch ECMV short circuit................................................................ 24
Failure code [DXH6KY] 3rd clutch ECMV hot short .................................................................... 26
Failure code [DXH7KA] Reverse clutch ECMV disconnection .................................................... 28
Failure code [DXH7KB] Reverse clutch ECMV short circuit........................................................ 30
Failure code [DXH7KY] Reverse clutch ECMV hot short ............................................................ 32
Failure code [DXH8KA] Forward clutch ECMV hot short ............................................................ 34
Failure code [DXH8KB] Forward clutch ECMV short circuit........................................................ 36
Failure code [DXH8KY] Forward clutch ECMV hot short ............................................................ 38
Failure code [DXH9KA] Right steering clutch ECMV disconnection ........................................... 40
Failure code [DXH9KB] Right steering clutch ECMV short circuit............................................... 42
Failure code [DXH9KY] Right steering clutch ECMV hot short ................................................... 44
Failure code [DXHAKA] Left steering clutch ECMV disconnection ............................................. 46
Failure code [DXHAKB] Left steering clutch ECMV short circuit ................................................. 48
Failure code [DXHAKY] Left steering clutch ECMV hot short ..................................................... 50
Failure code [DXHBKA] Right brake ECMV disconnection ......................................................... 52
Failure code [DXHBKB] Right brake ECMV short circuit............................................................. 54
Failure code [DXHBKY] Right brake ECMV hot short ................................................................. 56
Failure code [DXHCKA] Left brake ECMV disconnection ........................................................... 58
Failure code [DXHCKB] Left brake ECMV short circuit ............................................................... 60
Failure code [DXHCKY] Left brake ECMV hot short ................................................................... 62
Failure code [F@BBZL] (or VHMS LED display "n338") Engine blow-by pressure 
abnormally high level ........................................................................................................... 64
Failure code [F@BYNR] (or VHMS LED display "n362") Front exhaust temperature 
abnormally high level (2) ...................................................................................................... 66
Failure code [F@BYNS] (or VHMS LED display "n361") Front exhaust temperature 
Failure code [F@BZNR] (or VHMS LED display "n372") Rear exhaust temperature 
Failure code [F@BZNS] (or VHMS LED display "n371") Rear exhaust temperature 
Troubleshooting of electrical system (E-mode) SEN01875-02
E-1 The engine does not start ..................................................................................................... 4
E-2 Preheat does not operate (Manual preheating function) ...................................................... 9
E-3 The ripper pin puller cylinder does not operate .................................................................... 12
E-4 When the starting switch is ON, none of the machine monitor come on .............................. 14
E-5 When the starting switch is turned ON, the machine monitor completely remains lighted 
and does not go out ............................................................................................................. 16
E-6 When the starting switch is ON, the basic check item flashes.............................................. 18
E-7 While the engine is operating, any caution item flashes....................................................... 20
E-8 An emergency caution item flashes while the engine is running .......................................... 23
E-9 While the preheater is operating, the preheating pilot lamp does not come on.................... 28
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on 
(Dual tilt-mounted machine) ................................................................................................. 30
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp 
does not come on................................................................................................................. 30
E-12 The engine coolant temperature gauge does not indicate normally ................................... 31
E-13 Indication of the power train (torque converter) temperature gauge is abnormal ............... 32
12 D375A-5E0
E-14 The hydraulic oil temperature gauge does not indicate normally ....................................... 34
E-15 Indication of the fuel gauge is abnormal............................................................................. 35
E-16 Indications of gear speed and engine speed are abnormal................................................ 36
E-17 Indication of the shift mode service meter is abnormal ...................................................... 36
E-18 The switch module cannot be operated.............................................................................. 37
E-19 The warning lamp does not flash or does not go out.......................................................... 38
E-20 The alarm buzzer does not sound or does not stop ........................................................... 39
E-21 Auto shift down is not possible or is not released............................................................... 40
E-22 The alarm buzzer cannot be cancelled............................................................................... 41
E-23 The operator mode cannot be operated ............................................................................. 42
E-24 The service mode cannot be operated ............................................................................... 44
E-25 The back-up alarm does not sound .................................................................................... 46
E-26 The night light, the headlamp, the working lamp and the rear lamp on the panel do not 
come on ............................................................................................................................... 48
E-27 Air conditioner does not operate......................................................................................... 54
E-28 Orbcomm terminal does not operate normally (Data are not transmitted).......................... 58
E-29 Fan does not reverse.......................................................................................................... 60
E-30 Gear cannot be shifted ....................................................................................................... 62
E-31 Electric priming pump does not operate or does not stop automatically ............................ 64
Troubleshooting of hydraulic, mechanical system (H-mode) SEN01876-01
H-1 No force (no drawbar pull).................................................................................................... 4
H-2 No travel (at 2nd or 3rd speed) ............................................................................................ 6
H-3 No travel at all gear speeds.................................................................................................. 8
H-4 Machine travels only in one direction forward or in reverse ................................................. 10
H-5 Large time lag at gear speed shifting or forward-reverse shifting......................................... 11
H-6 Steering is not possible ........................................................................................................ 12
H-7 Steering is possible only on one side ................................................................................... 13
H-8 Steering overrun occurs ....................................................................................................... 14
H-9 Brake does not work............................................................................................................. 15
H-10 Torque converter is not lock-up .......................................................................................... 16
H-11 Power train oil overheats .................................................................................................... 17
H-12 All work equipment operates slowly ................................................................................... 18
H-13 All work equipment does not operate ................................................................................. 19
H-14 Blade lift speed is slow or lacks power ............................................................................... 20
H-15 Blade tilt speed is slow or lacks power............................................................................... 20
H-16 Ripper lift speed is slow or lacks power ............................................................................. 21
H-17 Ripper tilt speed is slow or lacks power ............................................................................. 21
H-18 Excessive hydraulic drift of blade lift................................................................................... 22
H-19 Excessive hydraulic drift of blade tilt .................................................................................. 23
H-20 Excessive hydraulic drift of ripper lift .................................................................................. 24
H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine)...................... 25
H-22 Blade pitch does not work (dual tilt attachment machine) .................................................. 26
H-23 Abnormal sound comes out from around work equipment pump ....................................... 27
H-24 Fan speed is abnormal (Sound and/or vibration are abnormally large or 
engine over heats) ............................................................................................................... 28
Troubleshooting of engine (S-mode) SEN01877-01
Method of using troubleshooting chart ........................................................................................ 3
S-1 Engine does not start easily ................................................................................................. 6
S-2 Engine does not start............................................................................................................ 8
S-3 Engine does not pick up smoothly (follow-up is poor) .......................................................... 12
S-4 Engine stops during operation .............................................................................................. 13
S-5 Engine does not rotate smoothly (hunting) ........................................................................... 14
S-6 Engine lacks output (or lacks power).................................................................................... 15
S-7 Exhaust smoke is black (Incomplete combustion)................................................................ 17
S-8 Oil is consumed much (or exhaust gas color is blue) ........................................................... 19
S-9 Engine oil becomes contaminated quickly............................................................................ 20
S-10 Fuel consumption is excessive........................................................................................... 21
D375A-5E0 13
S-11 Coolant contains oil (blows back or reduces)...................................................................... 22

S-12 Oil pressure lamp lights up (drop in oil pressure) ............................................................... 23
S-13 Oil level rises (Water, fuel in oil).......................................................................................... 24
S-14 Coolant temperature rises too high (Overheating).............................................................. 26
S-15 Abnormal noise is made ..................................................................................................... 27
S-16 Vibration is excessive ......................................................................................................... 28
S-17 Air cannot be bled from fuel circuit ..................................................................................... 30
50 Disassembly and assembly

General information on disassembly and assembly SEN02362-02
How to read this manual.............................................................................................................. 2
Coating materials list ................................................................................................................... 4
Special tool list............................................................................................................................. 7
Sketchs of special tools............................................................................................................... 17
Removal and installation of engine assembly ............................................................................. 2
Removal and installation of cooling assembly (radiator, aftercooler and hydraulic oil cooler)..... 7
Removal and installation of radiator ............................................................................................ 10
Removal and installation of hydraulic oil cooler .......................................................................... 12
Removal and installation of aftercooler ....................................................................................... 13
Removal and installation of radiator guard assembly.................................................................. 14
Removal and installation of fuel tank assembly .......................................................................... 18
Removal and installation of engine hood assembly .................................................................... 19
Removal and installation of fan drive assembly .......................................................................... 21
Removal and installation of fan motor assembly......................................................................... 23
Engine SEN02364-01
Removal and installation of fuel supply pump assembly ............................................................. 2
Removal and installation of cylinder head assembly................................................................... 6
Removal and installation of fuel injector assembly...................................................................... 22
Removal and installation of engine front seal.............................................................................. 27
Removal and installation of engine rear seal .............................................................................. 29
Removal and installation of damper assembly............................................................................ 2
Disassembly and assembly of damper........................................................................................ 6
Removal and installation of power train unit assembly ............................................................... 9
Disconnection and connection of power train unit assembly....................................................... 13
Disassembly and assembly of PTO assembly ............................................................................ 19
Disassembly and assembly of torque converter assembly ......................................................... 25
Disassembly and assembly of torqflow transmission assembly.................................................. 34
Disassembly and assembly of steering case assembly .............................................................. 2
Removal and installation of power train, lubrication pump assembly .......................................... 17
Removal and installation of scavenging pump assembly............................................................ 18
Removal and installation of final drive assembly......................................................................... 19
Disassembly and assembly of final drive assembly .................................................................... 20
Removal and installation of track frame assembly ...................................................................... 2
Removal and installation of idler assembly ................................................................................. 7
Disassembly and assembly of idler assembly............................................................................. 8
Removal and installation of recoil spring assembly..................................................................... 11
Disassembly and assembly of recoil spring assembly ................................................................ 16
Removal and installation track roller assembly ........................................................................... 18
Disassembly and assembly of track roller assembly................................................................... 21
Removal and installation of carrier roller assembly ..................................................................... 23
Disassembly and assembly of carrier roller assembly ................................................................ 24
Removal and installation of bogie assembly ............................................................................... 27
14 D375A-5E0
Disassembly and assembly of bogie assembly........................................................................... 32

Removal and installation of 1st bogie assembly ......................................................................... 34
Expansion and installation of track shoe assembly..................................................................... 2
Whole disassembly and assembly of track shoe ........................................................................ 5
Dimensions table of fitting jig of link press .................................................................................. 22
Disassembly and assembly of 1 link in the field .......................................................................... 23
Disassembly and assembly of master link .................................................................................. 27
Removal and installation of pivot shaft assembly........................................................................ 32
Removal and installation of equalizer bar ................................................................................... 33
Disassembly and assembly of equalizer bar bushing ................................................................. 36
Removal and installation of segment tooth ................................................................................. 38
Hydraulic system SEN02369-01
Removal and installation of hydraulic tank and control valve assembly...................................... 2
Removal and installation of work equipment pump assembly .................................................... 5
Removal and installation of fan pump assembly ......................................................................... 7
Removal and installation of control valve assembly.................................................................... 10
Assembly of control valve assembly ........................................................................................... 12
Disassembly and assembly of PPC charge valve assembly....................................................... 18
Disassembly and assembly of blade PPC valve assembly ......................................................... 19
Disassembly and assembly of ripper PPC valve assembly ........................................................ 21
Disassembly and assembly of hydraulic cylinder assembly........................................................ 22
Disassembly and assembly of ripper pin puller cylinder assembly ............................................. 27
Removal and installation of blade assembly ............................................................................... 2
Disassembly and assembly of blade assembly........................................................................... 4
Disassembly and assembly of giant ripper assembly ................................................................. 8
Removal and installation of ROPS guard.................................................................................... 2
Removal and installation of operator's cab assembly ................................................................. 3
Removal and installation of floor frame assembly....................................................................... 7
Removal and installation of transmission and steering controller assembly ............................... 2
Removal and installation of engine controller assembly ............................................................. 3
Removal and installation of VHMS controller assembly.............................................................. 5
Removal and installation of air conditioner unit assembly .......................................................... 6
Removal and installation of monitor panel assembly .................................................................. 9
90 Diagrams and drawings

Hydraulic diagrams and drawings SEN01007-02
Hydraulic circuit diagram (1/2) .................................................................................................... 3
Hydraulic circuit diagram (2/2) .................................................................................................... 5
Power train hydraulic circuit diagram .......................................................................................... 7
Electrical diagrams and drawings SEN01008-03
Electrical circuit diagram (1/13)................................................................................................... 3
Electrical circuit diagram (10/13)................................................................................................. 21
Electrical circuit diagram (11/13) ................................................................................................. 23
Electrical circuit diagram (12/13)................................................................................................. 25
D375A-5E0 15
Electrical circuit diagram (13/13) ................................................................................................. 27

Electrical circuit diagram for inside cab ....................................................................................... 29
Air conditioner unit electrical circuit diagram ............................................................................... 31
Connectors table and arrangement drawing ............................................................................... 33
16 D375A-5E0
D375A-5E0 17
D375A-5E0 Bulldozer
Form No. SEN00988-11

© 2009 KOMATSU
All Rights Reserved
Printed in Japan 09-09
18 D375A-5E0
SEN00989-04
BULLDOZER 1SHOP MANUAL
D375A-5E0
Machine model Serial number

D375A-5E0 50001 and up
00 Index and foreword 1

Foreword and general information
Safety notice ................................................................................................................................................... 2
How to read the shop manual ......................................................................................................................... 7
Explanation of terms for maintenance standard ............................................................................................. 9
Handling of electric equipment and hydraulic component .............................................................................11
Handling of connectors newly used for engines ........................................................................................... 20
How to read electric wire code...................................................................................................................... 23
Precautions when carrying out operation...................................................................................................... 26
Method of disassembling and connecting push-pull type coupler................................................................. 29
Standard tightening torque table ................................................................................................................... 32
Conversion table ........................................................................................................................................... 36
D375A-5E0 1
Safety notice 1
(Rev. 2008/08)
Important safety notice
Proper service and repair are extremely important for safe machine operation. The service and repair
techniques recommended by Komatsu and described in this manual are both effective and safe.
Some of these techniques require the use of tools specially designed by Komatsu for the specific
purpose.
To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The
cautions accompanying these symbols should always be followed carefully. If any dangerous situa-
tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with
the situation.
1. General precautions 7) If welding repairs are needed, always

k Mistakes in operation are extremely have a trained and experienced welder
dangerous. Read the Operation and carry out the work. When carrying out
Maintenance Manual carefully before weld in g wo rk , al way s wear wel din g
operating the machine. In addition, gloves, apron, shielding goggles, cap and
read this manual and understand its other clothes suited for welding work.
contents before starting the work. 8) Before starting work, warm up your body
1) Before carrying out any greasing or thoroughly to start work under good condi-
repairs, read all the safety labels stuck to tion.
the machine. For the locations of the 9) Avoid continuing work for long hours and
safety labels and detailed explanation of take rests at proper intervals to keep your
precautions, see the Operation and Main- body in good condition. Take rests in
tenance Manual. specified safe places.
2) Decide a place in the repair workshop to
keep tools and removed parts. Always Safety points
keep the tools and parts in their correct
places. Always keep the work area clean 1 Good arrangement
and make sure that there is no dirt, water, 2 Correct work clothes
or oil on the floor. Smoke only in the areas 3 Following work standard
provided for smoking. Never smoke while
working. 4 Making and checking signs
3) When carrying out any operation, always Prohibition of operation and handling by
5
wear safety shoes and helmet. Do not unlicensed workers
wear loose work clothes, or clothes with 6 Safety check before starting work
buttons missing.
Wearing protective goggles
q Always wear safety glasses when hit- 7
(for cleaning or grinding work)
ting parts with a hammer.
q Always wear safety glasses when Wearing shielding goggles and protectors
8
grinding parts with a grinder, etc. (for welding work)
4) When carrying out any operation with 2 or 9 Good physical condition and preparation
more workers, always agree on the oper- Precautions against work which you are
ating procedure before starting. Always 10
not used to or you are used to too much
inform your fellow workers before starting
any step of the operation. Before starting
work, hang UNDER REPAIR warning
signs 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, fork-
lift, service car, etc.
2 D375A-5E0
2. Preparations for work 6) When removing a cover which is under

1) Before adding oil or making any repairs, internal pressure or under pressure from a
park the machine on a hard and level spring, always leave 2 bolts in diagonal
ground, and apply the parking brake and positions. Loosen those bolts gradually
block the wheels or tracks to prevent the and alternately to release the pressure,
machine from moving. and then remove the cover.
2) Before starting work, lower the work 7) When removing components, be careful
equipment (blade, ripper, bucket, etc.) to not to break or damage the electrical wir-
the ground. If this is not possible, insert ing. Damaged wiring may cause electrical
the lock pin or use blocks to prevent the fires.
work equipment from falling. In addition, 8) When removing piping, stop the fuel or oil
be sure to lock all the control levers and from spilling out. If any fuel or oil drips
hang warning signs on them. onto the floor, wipe it up immediately. Fuel
3) When disassembling or assembling, sup- or oil on the floor can cause you to slip
port the machine with blocks, jacks, or and can even start fires.
stands before starting work. 9) As a general rule, do not use gasoline to
4) Remove all mud and oil from the steps or wash parts. Do not use it to clean electri-
other places used to get on and off the cal parts, in particular.
machine. Always use the handrails, lad- 10) Be sure to assemble all parts again in their
ders or steps when getting on or off the original places. Replace any damaged
m a c h i n e . N e v e r j u m p o n o r o ff t h e parts and parts which must not be reused
machine. If it is impossible to use the with new parts. When installing hoses and
handrails, ladders or steps, use a stand to wires, be sure that they will not be dam-
provide safe footing. aged by contact with other parts when the
machine is operated.
3. Precautions during work 11) When installing high pressure hoses,
1) Before disconnecting or removing compo- make sure that they are not twisted. Dam-
nents of the oil, water, or air circuits, first aged tubes are dangerous, so be
release the pressure completely from the extremely careful when installing tubes for
circuit. When removing the oil filler cap, a high pressure circuits. In addition, check
drain plug, or an oil pressure pickup plug, t h a t c o n n e c t i n g pa r ts a r e c o r r e c t l y
loosen it slowly to prevent the oil from installed.
spurting out. 12) When assembling or installing parts,
2) The coolant and oil in the circuits are hot always tighten them to the specified
when the engine is stopped, so be careful torques. When installing protective parts
not to get scalded. Wait for the oil and such as guards, or parts which vibrate vio-
coolant to cool before carrying out any lently or rotate at high speed, be particu-
work on the oil or water circuits. l a r ly c a r e fu l t o c he c k t h a t t h e y ar e
3) Before starting work, stop the engine. installed correctly.
When working on or around a rotating 13) When aligning 2 holes, never insert your
part, in particular, stop the engine. When fingers or hand. Be careful not to get your
checking the machine without stopping fingers caught in a hole.
the engine (measuring oil pressure, 14) When measuring hydraulic pressure,
revolving speed, temperature, etc.), take check that the measuring tools are cor-
extreme care not to get rolled or caught in rectly assembled.
rotating parts or moving parts. 15) Take care when removing or installing the
4) Before starting work, remove the leads tracks of track-type machines. When
from the battery. Always remove the lead removing the track, the track separates
from the negative (–) terminal first. suddenly, so never let anyone stand at
5) When raising a heavy component (heavier either end of the track.
than 25 kg), use a hoist or crane. Before 16) If the engine is operated for a long time in
starting work, check that the slings (wire a place which is not ventilated well, you
ropes, chains, and hooks) are free from may suffer from gas poisoning. Accord-
damage. Always use slings which have ingly, open the windows and doors to ven-
ample capacity and install them to proper tilate well.
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.
D375A-5E0 3
4. Precautions for sling work and making

signs
1) Only one appointed worker must make
signs and co-workers must communicate
with each other frequently. The appointed
sign maker must make specified signs
clearly at a place where he is well seen
from the operator's seat and where he can
see the working condition easily. The sign
maker 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.
8) When installing wire ropes to an angular
3) Keep putting on gloves during sling work.
load, apply pads to protect the wire ropes.
(Put on leather gloves, if available.)
If the load is slippery, apply proper mate-
4) Measure the weight of the load by the eye
rial to prevent the wire rope from slipping.
and check its center of gravity.
9) Use the specified eyebolts and fix wire
5) Use proper sling according to the weight
ropes, chains, etc. to them with shackles,
of the load and method of slinging. If too
etc.
thick wire ropes are used to sling a light
10) Apply wire ropes to the middle portion of
load, the load may slip and fall.
the hook.
6) Do not sling a load with 1 wire rope alone.
q Slinging near the tip of the hook may
If it is slung so, it may rotate and may slip
cause the rope to slip off the hook
out of the rope. Install 2 or more wire
during hoisting. The hook has the
ropes symmetrically.
k Slinging with 1 rope may cause
maximum strength at the middle por-
tion.
turning of the load during hoisting,
untwisting of the rope, or slipping
of the rope from its original wind-
ing position on the load, which can
result in a dangerous accident.
7) Limit the hanging angle to 60°, as a rule.
Do not sling a heavy load with ropes form-
ing 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 allow-
able 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 11) Do not use twisted or kinked wire ropes.
sling a load vertically, up to 19.6 kN {2,000 12) When lifting up a load, observe the follow-
kg} of total weight can be suspended. ing.
This weight is reduced to 9.8 kN {1,000 q Wind in the crane slowly until wire
kg} when the 2 ropes make a hanging ropes are stretched. When settling
angle of 120°. If the 2 ropes sling a 19.6 the wire ropes with the hand, do not
kN {2,000 kg} load at a lifting angle of grasp them but press them from
150°, each of them is subjected to a force above. If you grasp them, your fingers
as large as 39.2 kN {4,000 kg}. may be caught.
q After the wire ropes are stretched,
stop the crane and check the condi-
tion of the slung load, wire ropes, and
pads.
4 D375A-5E0
q If the load is unstable or the wire rope 13) If the hoist stops because of a power fail-
or chains are twisted, lower the load ure, turn the power switch OFF. When
and lift it up again. turning on a switch which was turned OFF
q Do not lift up the load slantingly. by the electric shock prevention earth
13) When lifting down a load, observe the fol- leakage breaker, check that the devices
lowing. related to that switch are not in operation
q When lifting down a load, stop it tem- state.
porarily at 30 cm above the floor, and 14) If you find an obstacle around the hoist,
then lower it slowly. stop the operation.
q Check that the load is stable, and 15) After finishing the work, stop the hoist at
then remove the sling. the specified position and raise the hook
q Remove kinks and dirt from the wire to at least 2 m above the floor. Do not
ropes and chains used for the sling leave the sling installed to the hook.
work, and put them in the specified
place. 7. Selecting wire ropes
1) Select adequate ropes depending on the
5. Precautions for using mobile crane weight of parts to be hoisted, referring to
a Read the Operation and Maintenance the table below.
Manual of the crane carefully in advance
and operate the crane safely. Wire ropes
(Standard “Z” twist ropes without galvanizing)
6. Precautions for using overhead hoist crane (JIS G3525, No. 6, Type 6X37-A)
k When raising a heavy part (heavier Nominal
Allowable load
than 25 kg), use a hoist, etc. In Disas- diameter of rope
sembly and assembly, the weight of a mm kN ton
part heavier than 25 kg is indicated 10 8.8 0.9
after the mark of 4. 12 12.7 1.3
1) Before starting work, inspect the wire 14 17.3 1.7
ropes, brake, clutch, controller, rails, over 16 22.6 2.3
wind stop device, electric shock preven- 18 28.6 2.9
tion earth leakage breaker, crane collision 20 35.3 3.6
prevention device, and power application
25 55.3 5.6
warning lamp, and check safety.
30 79.6 8.1
2) Observe the signs for sling work.
40 141.6 14.4
3) Operate the hoist at a safe place.
4) Check the direction indicator plates (east, 50 221.6 22.6
west, south, and north) and the directions 60 318.3 32.4
of the control buttons without fail.
5) Do not sling a load slantingly. Do not move a The allowable load is one-sixth of the
the crane while the slung load is swinging. breaking strength of the rope used
6) Do not raise or lower a load while the (Safety coefficient: 6).
crane is moving longitudinally or laterally.
7) Do not drag a sling.
8) When lifting up a load, stop it just after it
leaves the ground and check safety, and
then lift it up.
9) Consider the travel route in advance and
lift up a load to a safe height.
10) Place the control switch on a position
where it will not be an obstacle to work
and passage.
11) After operating the hoist, do not swing the
control switch.
12) Remember the position of the main switch
so that you can turn off the power immedi-
ately in an emergency.
D375A-5E0 5
8. Precautions for disconnecting and con- a Example of O-ring (Fitted to every joint of
necting hoses and tubes in air conditioner hoses and tubes)
circuit
1) Disconnection
k For the environment, the air condi-
tioner of this machine uses the
refrigerant (air conditioner gas:
R134a) which has fewer factors of
the depletion of the ozone layer.
However, it does not mean that you
may discharge the refrigerant into
the atmosphere as it is. Be sure to
recover the refrigerant when dis-
connecting the refrigerant gas cir-
cuit and then reuse it.
a Ask professional traders for collecting a For tightening torque, see the precautions for
and filling operation of refrigerant installation in each section of "Disassembly
(R134a). and assembly".
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 and your skin
may be frozen. Accordingly, put
on safety glasses, safety gloves
and safety clothes when recover-
ing or adding the refrigerant.
Refrigerant gas must be recovered
and added by a qualified person.
2) Connection
1] When installing the air conditioner cir-
cuit hoses and tubes, take care that
dirt, dust, water, etc. will not enter
them.
2] When connecting the air conditioner
hoses and tubes, check that O-rings
(1) are fitted to their joints.
3] Check that each O-ring is not dam-
aged or deteriorated.
4] When connecting the refrigerant pip-
ing, apply compressor oil for refriger-
ant (R134a) (DENSO: ND-OIL8,
VA L E O T H E R M A L S Y S T E M S :
ZXL100PG (equivalent to PAG46))
to its O-rings.
6 D375A-5E0
How to read the shop manual 1
q Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one
of them is required, consult KOMATSU distributors.
q Materials and specifications are subject to change without notice.
q Shop manuals are divided into the “Chassis volume” and “Engine volume”. For the engine unit, see the
engine volume of the engine model mounted on the machine.
1. Composition of shop manual

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

This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard

This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for dis-
assembly and service.
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 judgement 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.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
2. Revision and distribution

Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most
up-to-date information before you start any work.
D375A-5E0 7
3. Filing method
File by the brochures in the correct order of the form number printed in the shop manual composition
table.
q Revised edition mark

When a manual is revised, the ones and tens digits of the form number of each brochure is
increased by 1. (Example: 00, 01, 02 …)
q Revisions
Revised brochures are shown in the shop manual composition table.
4. Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will
be used practically.
Symbol Item Remarks
k Safety Special safety precautions are necessary when performing work.
Special technical precautions or other precautions for preserving stan-

a Caution
dards are necessary when performing work.
4
Weight of parts of component or parts. Caution necessary when
Weight
selecting hoisting wire, or when working posture is important, etc.
3
Tightening Places that require special attention for tightening torque during
torque assembly.
2 Coat Places to be coated with adhesives, etc. during assembly.
5
Oil, coolant Places where oil, etc. must be added, and capacity.
6
Drain Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, con-
ventionally used Gravitational System of units is indicated in parentheses { }.
8 D375A-5E0
Explanation of terms for maintenance standard 1

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 tem-
porary standard size is set and an allow-
able difference from that size is indicated.
q The above size set temporarily is called
the “standard size” and the range of differ-
ence 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
120
–0.126
a The tolerance may be indicated in the text

and a table as [standard size (upper limit
of tolerance/lower limit of tolerance)].
Example) 120 (–0.022/–0.126)
q Usually, the size of a hole and the size of

the shaft to be fitted to that hole are indi-
cated by the same standard size and dif-
ferent tolerances of the hole and shaft.
The tightness of fit is decided by the toler-
ance.
q Indication of size of rotating shaft and hole
and relationship drawing of them
Example:
Tolerance
Standard size
Shaft Hole
–0.030 +0.046
60
–0.076 +0
D375A-5E0 9
2. Standard clearance and standard value 5. Clearance limit

q The clearance made when new parts are q Parts can be used until the clearance
assembled is called the “standard clear- between them is increased to a certain
ance“, which is indicated by the range limit. The limit at which those parts cannot
from the minimum clearance to the maxi- be used is called the “clearance limit”.
mum clearance. q If the clearance between the parts
q When some parts are repaired, the clear- exceeds the clearance limit, they must be
ance is generally adjusted to the standard replaced or repaired.
clearance.
q A value of performance and function of 6. Interference limit
new products or equivalent is called the q The allowable maximum interference
“standard value“, which is indicated by a between the hole of a part and the shaft of
range or a target value. another part to be assembled is called the
q When some parts are repaired, the value “interference limit”.
of performance/function is set to the stan- q The interference limit shows the repair
dard value. limit of the part of smaller tolerance.
q If the interference between the parts
3. Standard interference exceeds the interference limit, they must
q When the diameter of a hole of a part be replaced or repaired.
shown in the given standard size and tol-
erance 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.
4. Repair limit and allowable value or allow-

able 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 prod-
uct 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 vari-
ous tests or experiences in most cases,
however, it must be judged after consider-
ing the operating condition and customer's
requirement.
10 D375A-5E0
Handling of electric equipment and hydraulic component 1

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

equipment
1. Handling wiring harnesses and connectors
Wiring harnesses consist of wiring connecting
one component to another component, con-
nectors used for connecting and disconnecting
one wire from another wire, and protectors or
tubes used for protecting the wiring.
Compared with other electrical components fit-
ted in boxes or cases, wiring harnesses are
more likely to be affected by the direct effects
of rain, water, heat, or vibration. Furthermore,
during inspection and repair operations, they
are 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 (defec-
tive contact between male and female)
Problems with defective contact are likely
to occur because the male connector is
not properly inserted into the female con-
nector, or because one or both of the con-
nectors is deformed or the position is not
correctly aligned, or because there is cor-
rosion or oxidization of the contact sur-
faces. The corroded or oxidized contact
surfaces may become shiny again (and
contact may become normal) by connect-
ing and disconnecting the connector about
10 times.
2) Defective crimping or soldering of connec-

tors
The pins of the male and female connec-
tors are in contact at the crimped terminal
or soldered portion, but if there is exces-
sive force brought to bear on the wiring,
the plating at the joint will peel and cause
improper connection or breakage.
D375A-5E0 11
3) Disconnections in wiring
If the wiring is held and the connectors are
pulled apart, or components are lifted with
a crane with the wiring still connected, or a
heavy object hits the wiring, the crimping
of the connector may separate, or the sol-
dering may be damaged, or the wiring
may be broken.
4) High-pressure water entering connector

The connector is designed to make it diffi-
cult for water to enter (drip-proof struc-
ture), 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-cir-
cuited 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 sur-
face between the male and female pins,
the oil will not let the electricity pass, so
there will be defective contact. If there is
oil or grease stuck to the connector, wipe it
off with a dry cloth or blow it dry with com-
pressed air and spray it with a contact
restorer.
a When wiping the mating portion of the
connector, be careful not to use
excessive force or deform the pins.
a If there is oil or water in the com-
pressed air, the contacts will become
even dirtier, so remove the oil and
water from the compressed air com-
pletely before cleaning with com-
pressed air.
12 D375A-5E0
3. Removing, installing, and drying connec-

tors and wiring harnesses
1) Disconnecting connectors
1] Hold the connectors when discon-
necting.
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 connec-
tors 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.
q When removing a connector from a

clip, pull the connector in a parallel
direction to the clip for removing stop-
pers.
a If the connector is twisted up and
down or to the left or right, the
housing may break.
3] Action to take after removing connec-

tors
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 disassem-
bled for a long time, it is particu-
larly easy for improper contact to
occur, so always cover the con-
nector.
D375A-5E0 13
2) Connecting connectors
1] Check the connector visually.
Check that there is no oil, dirt, or
water stuck to the connector pins
(mating portion).
Check that there is no deformation,
defective contact, corrosion, or dam-
age to the connector pins.
Check that there is no damage or
breakage to the outside of the con-
nector.
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 wiring with a
dryer, but be careful not to make
it too hot as this will cause short
circuits.
a If there is any damage or break-
age, replace the connector.
2] Fix the connector securely.
Align the position of the connector
correctly, and then insert it securely.
For connectors with the lock stopper,
push in the connector until the stop-
per clicks into position.
3] Correct any protrusion of the boot and
any misalignment of the wiring har-
ness.
For connectors fitted with boots, cor-
rect any protrusion of the boot. In
addition, if the wiring harness is mis-
aligned, or the clamp is out of posi-
tion, adjust it to its correct position.
a If the connector cannot be cor-
rected 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.
14 D375A-5E0
3) Heavy duty wire connector (DT 8-pole, 12- q Disconnection q Connection (Example of
pole) incomplete setting of (a))
Disconnection (Left of figure)
While pressing both sides of locks (a)
and (b), pull out female connector (2).
Connection (Right of figure)
1] Push in female connector (2) horizon-
tally 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
D375A-5E0 15
4) Drying wiring harness

If there is any oil or dirt on the wiring har-
ness, 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 fol-
lows.
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
oi l a nd wa ter fr om t he c om -
pressed 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 con-
nector.
After drying, leave the wiring harness
disconnected and carry out a continu-
ity test to check for any short circuits
between pins caused by water.
a After completely drying the con-
n e c t o r, b l o w i t w i t h c o n ta c t
restorer and reassemble.
16 D375A-5E0
4. Handling controller
1) The controller contains a microcomputer
and electronic control circuits. These con-
trol 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 control-
ler.
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
body, disconnect all wiring harness con-
nectors connected to the controller. Fit an
arc welding ground close to the welding
point.
5. Points to remember when troubleshooting

electric circuits
1) Always turn the power OFF before discon-
necting or connecting connectors.
2) Before carrying out troubleshooting, check
that all the related connectors are properly
inserted.
a Disconnect and connect the related
connectors several times to check.
3) Always connect any disconnected con-
nectors before going on to the next step.
a If the power is turned ON with the
connectors still disconnected, unnec-
essary abnormality displays will be
generated.
4) When carrying out troubleshooting of cir-
cuits (measuring the voltage, resistance,
continuity, or current), move the related
wiring and connectors several times and
check that there is no change in the read-
ing of the tester.
a If there is any change, there is proba-
bly defective contact in that circuit.
D375A-5E0 17
Points to remember when handling hydraulic equipment

With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt
(foreign material) in the hydraulic circuit. When adding hydraulic oil, or when disassembling or assembling
hydraulic equipment, it is necessary to be particularly careful.
1. Be careful of the operating environment.

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

field
If disassembly or maintenance work is carried
out on hydraulic equipment in the field, there is
danger of dust entering the equipment. It is
also difficult to check the performance after
repairs, so it is desirable to use unit exchange.
Disassembly and maintenance of hydraulic
equipment should be carried out in a specially
prepared dustproof workshop, and the perfor-
mance should be checked with special test
equipment.
3. Sealing openings
After any piping or equipment is removed, the
openings should be sealed with caps, tapes, or
vinyl bags to prevent any dirt or dust from
entering. If the opening is left open or is
blocked with a rag, there is danger of dirt
entering or of the surrounding area being
made dirty by leaking oil so never do this. Do
not simply drain oil out onto the ground, but
collect it and ask the customer to dispose of it,
or take it back with you for disposal.
4. 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 clean-
ing device is used, it is possible to filter out the
dirt that has collected during storage, so this is
an even more effective method.
18 D375A-5E0
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 equip-
ment, or changing the oil, use flushing oil to
remove the contaminants, sludge, and old oil
from the hydraulic circuit. Normally, flushing is
carried out twice: primary flushing is carried
out with flushing oil, and secondary flushing is
carried out with the specified hydraulic oil.
7. Cleaning operations
After repairing the hydraulic equipment (pump,
control valve, etc.) or when running the
machine, carry out oil cleaning to remove the
sludge or contaminants in the hydraulic oil cir-
cuit. The oil cleaning equipment is used to
remove the ultra fine (about 3 m) particles that
the filter built in the hydraulic equipment can-
not remove, so it is an extremely effective
device.
D375A-5E0 19
Handling of connectors newly used for engines 1

a Mainly, following engines are object for follow- 2. Pull lock type (PACKARD-2)
ing connectors. q 95 – 170, 12V140 engines
q 95E-5 q Various temperature sensors
q 107E-1 Example)
q 114E-3 Intake air temperature sensor in
q 125E-5 intake manifold: TIM
q 140E-5 Fuel temperature sensor: TFUEL
q 170E-5 Oil temperature sensor: TOIL
q 12V140E-3 Coolant temperature sensor: TWTR,
etc.
1. Slide lock type Disconnect the connector by pulling lock
(FRAMATOME-3, FRAMATOME-2) (B) (on the wiring harness side) of connec-
q 95 – 170, 12V140 engines tor (2) outward.
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)
Disconnect connector (1) according to the fol-

lowing procedure.
1) Slide lock (L1) to the right.
2) While pressing lock (L2), pull out connec-
tor (1) toward you.
a Even if lock (L2) is pressed, connec-
tor (1) cannot be pulled out toward
you, if part A does not float. In this
case, float part A with a small screw-
driver while press lock (L2), and then
pull out connector (1) toward you.
20 D375A-5E0
Thank you very much
for your reading.
Please Click Here
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SEN00986-11

BULLDOZER D375A -5E0

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

Composition of shop manual 1

Section Title Form Number

Shop Manual, contents binder, binder label and tabs SEN00986-11

00 Index and foreword SEN00987-11

10 Structure, function and maintenance standard SEN00992-04

20 Standard value table SEN01002-01

30 Testing and adjusting SEN01003-04

Troubleshooting by failure code, Part 5 SEN01873-02

50 Disassembly and assembly SEN01005-02

90 Diagrams and drawings SEN01006-04

Foreword and general information SEN00989-04

10 Structure, function and maintenance standard

Recoil spring ............................................................................................................................... 4

20 Standard value table

30 Testing and adjusting

Using method of KOMTRAX functions of ORBCOMM terminal .................................................. 33

Failure code [DB3SKR] Steering controller S-NET communication error.................................... 24

Failure code [DXH1KA] Lockup solenoid disconnection ............................................................. 4

S-11 Coolant contains oil (blows back or reduces)...................................................................... 22

50 Disassembly and assembly

Disassembly and assembly of bogie assembly........................................................................... 32

90 Diagrams and drawings

Electrical circuit diagram (13/13) ................................................................................................. 27

BULLDOZER 1SHOP MANUAL

Machine model Serial number

00 Index and foreword 1

1. General precautions 7) If welding repairs are needed, always

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

4. Precautions for sling work and making

How to read the shop manual 1

1. Composition of shop manual

00. Index and foreword

10. Structure, function and maintenance standard

20. Standard value table

30. Testing and adjusting

50. Disassembly and assembly

2. Revision and distribution

q Revised edition mark

Symbol Item Remarks

k Safety Special safety precautions are necessary when performing work.

Special technical precautions or other precautions for preserving stan-

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

Explanation of terms for maintenance standard 1

1. Standard size and tolerance

a The tolerance may be indicated in the text

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

2. Standard clearance and standard value 5. Clearance limit

4. Repair limit and allowable value or allow-

Handling of electric equipment and hydraulic component 1

Points to remember when handling electric

2. Main failures occurring in wiring harness

2) Defective crimping or soldering of connec-

4) High-pressure water entering connector

5) Oil or dirt stuck to connector