Komatsu Bulldozer D375A-5E0 Shop Manual SEN00986-15 PDF DOWNLOAD

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Komatsu Bulldozer D375A-5E0 Shop Manual SEN00986-15 –  PDF DOWNLOAD

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Komatsu Bulldozer D375A-5E0 Shop Manual SEN00986-15 –  PDF DOWNLOAD

Language : English
Pages : 1654
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer D375A-5E0 Shop Manual SEN00986-15 –  PDF DOWNLOAD

• SERIAL NUMBERS 50001 and up

COVER . 1
00 Index and foreword . 0
Index . 3
Composition of shop manual 4
Table of conten . 6
Foreword and general information 21
Safety notice . 22
How to read the shop manual . 27
Explanation of terms for maintenance standard . 29
Handling of electric equipment and hydraulic component 31
Handling of connectors newly used for engines . 40
How to read electric wire code 43
Precautions when carrying out operation . 46
Method of disassembling and connecting push-pull type coupler . 49
Standard tightening torque table 52
Conversion table 56
01 Specification 0
Specification and technical data 63
Specification drawing . 64
Specifications 65
Weight table 70
Table of fuel, coolant and lubricants . 72
10 Structure, function and maintenance standard . 0
Engine and cooling system . 75
Engine mount 76
Cooling system 78
Cooling fan pump 80
Cooling fan motor . 96
Power train, Part 1 . 105
Power train . 106
Overall drawing of power train unit . 108
Power train hydraulic piping drawing 110
Damper, universal joint . 112
Torque converter, PTO . 114
Scavenging pump . 121
Torque converter valve 122
Power train, Part 2 . 137
Transmission control 138
Transmission 144
Transmission ECMV . 158
Transmission lubrication relief valve . 164
Power train pump + lubrication pump . 165
Steering, brake control . 166
Transfer, bevel gear shaft, steering 168
Steering ECMV . 178
Steering clutch ECMV, Steering brake ECMV . 182
Parking brake valve . 189
Sudden stop prevention valve 190
Final drive . 191
Sprocket 196
Undercarriage and frame . 199
Track frame . 200
Recoil spring . 202
Idler . 204
Track roller 206
Carrier roller 208
Track roller bogie 209
Track shoe 210
Main frame 214
Suspension 216
Hydraulic system, Part 1 221
Work equipment hydraulic piping diagram . 222
PPC control piping diagram 226
Work equipment control 228
Hydraulic tank 230
Accumulator . 232
PPC lock valve 233
PPC valve . 234
Hydraulic cylinder 248
Piston valve 252
Quick drop valve 253
Pin puller switch . 255
Pin puller solenoid valve . 256
Blade control knob (Only the machine with dual tilt) 258
Pitch, dual tilt solenoid valve . 259
Work equipment pump . 262
Hydraulic system, Part 2 265
Control valve . 266
Self pressure reducing valve 298
Work equipment 307
Cylinder stay . 308
Blade . 310
Cutting edge, end bit . 314
Ripper 316
Cab and its attachments . 319
Cab mount . 320
Cab . 321
Air conditioner . 323
Electrical system . 325
Engine control system . 326
CRI engine control system . 336
Monitor system 338
Machine monitor . 340
Mode selection system . 354
Electrical equipment 358
Palm command control system . 360
Sensors . 362
Vehicle health monitoring system (VHMS) . 366
ORBCOMM terminal system . 372
20 Standard value table . 0
Standard service value table 377
Standard value table for engine . 378
Standard value table for machine 379
30 Testing and adjusting 0
Testing and adjusting, Part 1 . 389
Tools for testing, adjusting, and troubleshooting . 391
Testing engine speed 394
Testing intake air pressure (boost pressure) 397
Testing exhaust temperature . 399
Testing exhaust gas color . 401
Adjusting valve clearance . 403
Testing compression pressure 405
Testing blow-by pressure 408
Testing engine oil pressure . 409
Testing EGR valve and bypass valve drive oil pressure . 410
Handling of fuel system devices . 412
Releasing residual pressure from fuel system 412
Testing fuel pressure . 413
Handling of reduced cylinder mode operation . 414
Handling of no injection cranking operation . 414
Testing leakage from pressure limiter and return rate from injector . 415
Bleeding air from fuel circuit 418
Testing fuel circuit for leakage 420
Handling controller voltage circuit . 421
Replacing and adjusting alternator and air conditioner compressor belt 421
Testing fan motor speed . 422
Testing fan circuit oil pressure 424
Bleeding air from fan pump 425
Adjusting fuel control dial and decelerator pedal . 426
Testing and adjusting, Part 2 . 429
Testing power train oil pressure 431
Adjusting transmission speed sensor . 441
Simple procedure for testing brake performance 442
Adjusting brake pedal and parking brake lever . 444
Adjusting position of pccs lever console 447
Emergency escape method when there is failure in power train 448
Inspecting wear of sprocket . 450
Testing and adjusting track shoe tension 451
Testing work equipment oil pressure . 452
Testing control circuit main pressure . 455
Testing PPC valve output pressure . 456
Adjusting play of PPC valve . 458
Testing output pressure of ripper pin-puller solenoid valve . 459
Checking location of cause of hydraulic drift of blade and ripper . 460
Testing leakage inside work equipment cylinder 461
Releasing remaining pressure in work equipment cylinders 462
Bleeding air from work equipment cylinders 462
Adjusting ripper lever position . 463
Adjusting work equipment lock lever . 464
Testing and adjusting operator’s cab 465
Adjusting blade . 469
Testing and adjusting, Part 3 . 473
Special functions of monitor panel (EMMS) . 474
Testing and adjusting, Part 4 . 525
Adjustment method when controller has been replaced . 526
Preparation work for troubleshooting for electrical equipment system 528
Inspection procedure of diode . 531
Handling of optional devices 532
Request for opening ORBCOMM terminal 533
Initialization procedures for VHMS controller . 535
Using method of KOMTRAX functions of ORBCOMM terminal . 557
Precautions for replacing VHMS controller . 560
Pm Clinic service . 566
40 Troubleshooting 0
Failure code table and fuse locations . 581
Failure codes table . 582
Fuse locations 592
General information on troubleshooting 597
Points to remember when troubleshooting . 598
Sequence of events in troubleshooting . 599
Check before troubleshooting 600
Classification and procedures for troubleshooting . 601
Information in troubleshooting table 604
Connection table for connector pin numbers 606
T- branch box and T- branch adapter table . 642
Troubleshooting by failure code, Part 1 . 647
Failure code [1380MW] Lockup clutch slip 649
Failure code [1500L0] Transmission clutch dual engagement . 650
Failure code [15E0MW] Transmission clutch slip 651
Failure code [15SAL1] When forward clutch oil pressure command current is OFF, fill signal is ON 652
Failure code [15SALH] When forward clutch oil pressure command current is ON, fill signal is OFF 654
Failure code [15SBL1] When reverse clutch oil pressure command current is OFF, fill signal is ON 656
Failure code [15SBLH] When reverse clutch oil pressure command current is ON, fill signal is OFF 658
Failure code [15SEL1] When 1st clutch oil pressure command current is OFF, fill signal is ON 660
Failure code [15SELH] When 1st clutch oil pressure command current is ON, fill signal is OFF 662
Failure code [15SFL1] When 2nd clutch oil pressure command current is OFF, fill signal is ON 664
Failure code [15SFLH] When 2nd clutch oil pressure command current is ON, fill signal is OFF 666
Failure code [15SGL1] When 3rd clutch oil pressure command current is OFF, fill signal is ON 668
Failure code [15SGLH] When 3rd clutch oil pressure command current is ON, fill signal is OFF 670
Failure code [1800MW] Power train clutch slip . 672
Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON . 674
Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF . 676
Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON 678
Failure code [2202LH] When left steering clutch oil pressure command current is ON, fill signal is OFF 680
Failure code [2300NR] Brake thermal load abnormality 682
Failure code [2301L1] When right steering brake oil pressure command current is OFF, fill signal is ON 684
Failure code [2301LH] When right steering brake oil pressure command current is ON, fill signal is OFF 686
Failure code [2301NR] Right steering brake thermal load abnormality . 688
Failure code [2302L1] When left steering brake oil pressure command current is OFF, fill signal is ON . 690
Failure code [2302LH] When left steering brake oil pressure command current is ON, fill signal is OFF . 692
Failure code [2302NR] Left steering brake thermal load abnormality 694
Failure code [6001ZK] Failure code for design . 694
Failure code [A000NS] Engine overheat . 695
Failure code [AA10NX] Air cleaner clogging 696
Failure code [AB00MA] Alternator malfunction 697
Failure code [B@BAZG] Engine oil pressure low . 698
Failure code [B@BAZK] Engine oil level reduction 699
Failure code [B@BCNS] Engine coolant overheat . 700
Failure code [B@BCZK] Radiator coolant level reduction 701
Failure code [B@BEBF] Water in engine fuel 702
Failure code [B@BFZK] Fuel level reduction 703
Failure code [B@CENS] Power train oil overheat 704
Failure code [B@CHZG] HSS charge oil pressure reduction . 705
Failure code [B@CHZK] Power train oil level reduction . 705
Failure code [B@GAZK] Battery electrolyte level reduction . 706
Failure code [B@HANS] Hydraulic oil overheat 706
Failure code [B@HAZK] Hydraulic oil level reduction . 707
Troubleshooting by failure code, Part 2 . 709
Failure code [CA111] Engine controller internal abnormality . 712
Failure code [CA115] Engine Ne/Bkup speed sensor abnormality 714
Failure code [CA122] Charge pressure sensor abnormally high level . 716
Failure code [CA123] Charge pressure sensor abnormally low level 718
Failure code [CA131] Throttle sensor abnormally high level 720
Failure code [CA132] Throttle sensor abnormally low level . 722
Failure code [CA135] Engine oil pressure sensor abnormally high level . 724
Failure code [CA141] Engine oil pressure sensor abnormally low level 726
Failure code [CA144] Coolant temperature sensor abnormally high level . 728
Failure code [CA145] Coolant temperature sensor abnormally low level 730
Failure code [CA153] Charge temperature sensor abnormally high level 732
Failure code [CA154] Charge temperature sensor abnormally low level . 734
Failure code [CA187] Sensor power supply 2 abnormally low level . 735
Failure code [CA212] Engine oil temperature sensor abnormally high level 736
Failure code [CA213] Engine oil temperature sensor abnormally low level . 738
Failure code [CA221] Ambient temperature sensor abnormally high level . 740
Failure code [CA222] Ambient temperature sensor abnormally low level 742
Failure code [CA227] Sensor power supply 2 abnormally high level 744
Failure code [CA234] Engine overspeed . 746
Failure code [CA238] Ne speed sensor power supply abnormality . 748
Failure code [CA263] Fuel temperature sensor abnormally high level 750
Failure code [CA265] Fuel temperature sensor abnormally low level . 752
Failure code [CA271] PCV1 short circuit . 754
Failure code [CA272] PCV1 disconnection . 756
Failure code [CA273] PCV2 short circuit . 758
Failure code [CA274] PCV2 disconnection . 760
Failure code [CA322] Injector #1 system disconnection or short circuit 762
Failure code [CA323] Injector #5 system disconnection or short circuit 764
Failure code [CA324] Injector #3 system disconnection or short circuit 766
Failure code [CA325] Injector #6 system disconnection or short circuit 768
Failure code [CA331] Injector #2 system disconnection or short circuit 770
Failure code [CA332] Injector #4 system disconnection or short circuit 772
Failure code [CA342] Engine controller data mismatch 774
Failure code [CA351] Injector drive circuit abnormality . 776
Failure code [CA352] Sensor power supply 1 abnormally low level . 778
Failure code [CA386] Sensor power supply 1 abnormally high level 780
Failure code [CA441] Power supply voltage abnormally low level 782
Failure code [CA442] Power supply voltage abnormally high level . 782
Failure code [CA449] Common rail pressure abnormally high pressure 2 783
Failure code [CA451] Common rail pressure sensor abnormally high level 784
Failure code [CA452] Common rail pressure sensor abnormally low level . 786
Failure code [CA553] Common rail pressure abnormally high pressure 1 787
Failure code [CA554] Common rail pressure sensor in-range abnormality . 788
Failure code [CA559] Supply pump low pressure 1 . 789
Failure code [CA689] Engine Ne speed sensor abnormality . 794
Failure code [CA731] Engine Bkup speed sensor phase abnormality . 796
Failure code [CA757] Engine controller all data loss 797
Failure code [CA778] Engine Bkup speed sensor abnormality . 798
Troubleshooting by failure code, Part 3 . 801
Failure code [CA1228] EGR valve servo abnormality 1 . 803
Failure code [CA1625] EGR valve servo abnormality 2 . 804
Failure code [CA1633] CAN communication error (Engine controller) . 806
Failure code [CA2185] Throttle sensor power supply abnormally high level 808
Failure code [CA2186] Throttle sensor power supply abnormally low level . 810
Failure code [CA2249] Supply pump low pressure 2 811
Failure code [CA2271] EGR valve lift sensor abnormally high level . 812
Failure code [CA2272] EGR valve lift sensor abnormally low level 814
Failure code [CA2351] EGR valve solenoid drive short circuit 816
Failure code [CA2352] EGR valve solenoid drive disconnection 818
Failure code [D110KA] Battery relay hold line disconnection . 820
Failure code [D110KB] Battery relay hold line short circuit . 822
Failure code [D130KA] Neutral safety relay disconnection 824
Failure code [D130KB] Neutral safety relay short circuit 826
Failure code [D161KA] Backup alarm relay disconnection 828
Failure code [D161KB] Backup alarm relay short circuit 830
Failure code [D182KZ] Preheater relay disconnection or short circuit 832
Failure code [D190KA] Engine controller ACC signal cut relay disconnection 834
Failure code [D190KB] Engine controller ACC signal cut relay short circuit 836
Failure code [D5ZRKA] Snap shot switch disconnection 838
Failure code [D5ZRKB] Snap shot switch short circuit 839
Failure code [DAFRKR] Machine monitor CAN communication error . 840
Failure code [daFRKR] Machine monitor CAN communication error . 842
Failure code [dAFRKR] Machine monitor CAN communication error . 844
Failure code [DAQ0KT] Transmission controller internal abnormality 846
Failure code [DAQ1KK] Transmission controller main power supply voltage reduction . 848
Failure code [DAQ2KK] Transmission controller load power supply voltage reduction . 850
Failure code [DAQ5KK] Transmission controller sensor 5V power supply (1) voltage reduction 852
Failure code [DAQ6KK] Transmission controller sensor 24V power supply voltage reduction . 854
Failure code [DAQ7KK] Transmission controller sensor 5V power supply (2) voltage reduction 856
Failure code [DAQ9KQ] Transmission controller model selection signal disagreement . 858
Failure code [DAQRKR] Transmission controller CAN communication error . 860
Failure code [DAQSKR] Transmission controller S-NET communication error . 862
Troubleshooting by failure code, Part 4 . 865
Failure code [DB2RKR] Engine controller CAN communication error . 868
Failure code [dB2RKR] Engine controller CAN communication error . 870
Failure code [DB30KT] Steering controller internal abnormality 872
Failure code [DB31KK] Steering controller main power supply voltage reduction . 874
Failure code [DB32KK] Steering controller load power supply voltage reduction . 876
Failure code [DB35KK] Steering controller sensor 5V power supply (1) voltage reduction 878
Failure code [DB36KK] Steering controller sensor 24V power supply voltage reduction . 880
Failure code [DB37KK] Steering controller sensor 5V power supply (2) voltage reduction 882
Failure code [DB39KQ] Steering controller model selection signal disagreement . 884
Failure code [dB3RKR] Steering controller CAN communication error . 886
Failure code [DB3SKR] Steering controller S-NET communication error . 888
Failure code [DBB0KK] (or VHMS LED display “n901”) VHMS supply voltage abnormality 890
Failure code [DBB0KQ] (or VHMS LED display “nF11”) VHMS connector connection abnormality 892
Failure code [DBB3KK] (or VHMS LED display “n905”) VHMS controller battery direct power supply voltage reduction 894
Failure code [DBB5KP] (or VHMS LED display “n904”) Sensor power supply (5V) system abnormality 896
Failure code [DBB6KP] (or VHMS LED display “n902”) Sensor power supply (24V) system disconnection or short circuit 898
Failure code [DBB7KP] (or VHMS LED display “n903”) Sensor power supply (12V) system disconnection or short circuit 900
Failure code [DBBQKR] (or VHMS LED display “n802”) CAN communication error (VHMS controller) 902
Failure code [dbBRKR] VHMS controller CAN communication error . 906
Failure code [DD12KA] Shift-up switch disconnection . 908
Failure code [DD12KB] Shift-up switch short circuit . 910
Failure code [DD13KA] Shift-down switch disconnection . 912
Failure code [DD13KB] Shift-down switch short circuit . 914
Failure code [DD14KA] Parking brake lever switch disconnection 916
Failure code [DD14KB] Parking brake lever switch short circuit 918
Failure code [DDB9L4] Reverse switch disagreement . 920
Failure code [DDK3L4] Forward switch signal disagreement 922
Troubleshooting by failure code, Part 5 . 925
Failure code [DDK5KA] Shift switch disconnection 928
Failure code [DDK5KB] Shift switch short circuit 930
Failure code [DDN2LD] Blade tilt right oil pressure switch is held down for long time . 932
Failure code [DDN3LD] Blade tilt left oil pressure switch is held down for long time 934
Failure code [DDN7KA] Blade pitch switch disconnection 936
Failure code [DDN7KB] Blade pitch switch short circuit 938
Failure code [DDN9KA] Blade tilt switch disconnection . 940
Failure code [DDN9KB] Blade tilt switch short circuit . 942
Failure code [DDNALD] Blade lift raise oil pressure switch is held down for long time . 944
Failure code [DDNBLD] Ripper lift raise oil pressure switch is held down for long time 946
Failure code [DDNCLD] Ripper lift lower oil pressure switch is held down for long time 948
Failure code [DDNDLD] Ripper tilt in oil pressure switch is held down for long time . 950
Failure code [DDNELD] Ripper tilt back oil pressure switch is held down for long time . 952
Failure code [DDNFLD] Blade lift lower oil pressure switch is held down for long time . 954
Failure code [DDQ2KA] Parking brake lever switch disconnection 956
Failure code [DDQ2KB] Parking brake lever switch short circuit 958
Failure code [DDQ2L4] Parking brake lever switch ON/OFF signal disagreement . 960
Failure code [dDQ2L4] Parking brake lever switch ON/OFF signal disagreement . 961
Failure code [DDT5KA] Neutral switch disconnection 962
Failure code [DDT5KB] Neutral switch short circuit 964
Failure code [DDT5KQ] Lever specification selection signal disagreement . 966
Failure code [DGE5KX] (or VHMS LED display “n40”) Ambient temperature sensor system disconnection or short circuit 968
Failure code [DGS1KX] Hydraulic oil temperature sensor signal out of range 970
Failure code [DGT1KA] Power train oil temperature sensor disconnection 972
Failure code [DGT1KX] Power train oil temperature sensor input signal out of range 974
Failure code [DGT5KA] (or VHMS LED display “n322”) Front exhaust temperature sensor system short circuit 976
Failure code [DGT5KB] (or VHMS LED display “n321”) Front exhaust temperature sensor system disconnection 978
Failure code [DGT6KA] (or VHMS LED display “n312”) Rear exhaust temperature sensor system short circuit . 980
Failure code [DGT6KB] (or VHMS LED display “n311”) Rear exhaust temperature sensor system disconnection . 982
Failure code [DH22KA] Work equipment pump oil pressure sensor 1 disconnection . 984
Failure code [DH22KB] Work equipment pump oil pressure sensor 1 short circuit . 986
Failure code [DH23KA] Work equipment pump oil pressure sensor 2 disconnection . 988
Failure code [DH23KB] Work equipment pump oil pressure sensor 2 short circuit . 990
Failure code [DHE5KB] (or VHMS LED display “n332”) Engine blow-by pressure sensor system disconnection 992
Failure code [DHE5KY] (or VHMS LED display “n331”) Engine blow-by pressure sensor system short circuit 994
Failure code [DHT3KX] (or VHMS LED display “n614”) Transmission oil pressure sensor input signal out of range . 996
Failure code [DK10KA] Fuel control dial disconnection . 998
Failure code [DK10KB] Fuel control dial short circuit .1000
Troubleshooting by failure code, Part 6 .1003
Failure code [DK30KA] Steering potentiometer 1 disconnection 1006
Failure code [DK30KB] Steering potentiometer 1 short circuit 1008
Failure code [DK30KX] Steering potentiometer 1 input signal out of range 1010
Failure code [DK30KZ] Steering potentiometer 1 disconnection or short circuit .1011
Failure code [DK30L8] Steering potentiometer 1 analog signal disagreement .1012
Failure code [DK31KA] Steering potentiometer 2 disconnection 1014
Failure code [DK31KB] Steering potentiometer 2 short circuit 1016
Failure code [DK40KA] Brake potentiometer disconnection .1018
Failure code [DK40KB] Brake potentiometer short circuit .1020
Failure code [DK55KX] Direction potentiometer input signal out of range .1022
Failure code [DK55KZ] Direction potentiometer disconnection or short circuit 1023
Failure code [DK55L8] Direction potentiometer analog signal disagreement 1024
Failure code [DK56KA] Direction potentiometer 1 disconnection .1026
Failure code [DK56KB] Direction potentiometer 1 short circuit .1028
Failure code [DK57KA] Direction potentiometer 2 disconnection .1030
Failure code [DK57KB] Direction potentiometer 2 short circuit .1032
Failure code [DK60KA] Acceleration sensor disconnection .1034
Failure code [DK60KB] Acceleration sensor short circuit .1036
Failure code [DKH1KA] Pitch angle sensor disconnection 1038
Failure code [DKH1KB] Pitch angle sensor short circuit 1040
Failure code [DKH1KX] Pitch angle sensor input signal out of range 1041
Failure code [DLF1KA] Torque converter output speed sensor disconnection 1042
Failure code [DLT3KA] Transmission output speed sensor disconnection 1 1043
Failure code [dLT3KA] Transmission output speed sensor disconnection 2 1044
Failure code [DLT3KB] Transmission output speed sensor short circuit 1045
Failure code [DV00KB] Alarm buzzer short circuit 1046
Failure code [DW59KA] Blade dual selector solenoid disconnection 1047
Failure code [DW59KB] Blade dual selector solenoid short circuit 1048
Failure code [DW59KY] Blade dual selector solenoid hot short 1049
Failure code [DW5AKA] Blade pitch selector solenoid disconnection .1050
Failure code [DW5AKB] Blade pitch selector solenoid short circuit .1051
Failure code [DW5AKY] Blade pitch selector solenoid hot short .1052
Failure code [DW7BKA] Fan reverse solenoid disconnection 1053
Failure code [DW7BKB] Fan reverse solenoid short circuit 1054
Failure code [DW7BKY] Fan reverse solenoid hot short 1055
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection .1056
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit .1058
Failure code [DWN3KY] Sudden stop prevention solenoid hot short .1060
Failure code [DWN5KA] Fan pulley solenoid 1 disconnection .1062
Failure code [DWN5KB] Fan pulley solenoid 1 short circuit .1064
Failure code [DWN5KY] Fan pulley solenoid 1 hot short .1066
Failure code [DWNCKA] Fan pulley solenoid 2 disconnection .1068
Failure code [DWNCKB] Fan pulley solenoid 2 short circuit .1070
Failure code [DWNCKY] Fan pulley solenoid 2 hot short .1072
Troubleshooting by failure code, Part 7 .1075
Failure code [DXH1KA] Lockup solenoid disconnection .1078
Failure code [DXH1KB] Lockup solenoid short circuit .1080
Failure code [DXH1KY] Lockup solenoid hot short .1082
Failure code [DXH4KA] 1st clutch ECMV disconnection .1084
Failure code [DXH4KB] 1st clutch ECMV short circuit .1086
Failure code [DXH4KY] 1st clutch ECMV hot short .1088
Failure code [DXH5KA] 2nd clutch ECMV disconnection .1090
Failure code [DXH5KB] 2nd clutch ECMV short circuit .1092
Failure code [DXH5KY] 2nd clutch ECMV hot short .1094
Failure code [DXH6KA] 3rd clutch ECMV disconnection .1096
Failure code [DXH6KB] 3rd clutch ECMV short circuit .1098
Failure code [DXH6KY] 3rd clutch ECMV hot short .1100
Failure code [DXH7KA] Reverse clutch ECMV disconnection .1102
Failure code [DXH7KB] Reverse clutch ECMV short circuit .1104
Failure code [DXH7KY] Reverse clutch ECMV hot short .1106
Failure code [DXH8KA] Forward clutch ECMV hot short .1108
Failure code [DXH8KB] Forward clutch ECMV short circuit .1110
Failure code [DXH8KY] Forward clutch ECMV hot short .1112
Failure code [DXH9KA] Right steering clutch ECMV disconnection 1114
Failure code [DXH9KB] Right steering clutch ECMV short circuit 1116
Failure code [DXH9KY] Right steering clutch ECMV hot short 1118
Failure code [DXHAKA] Left steering clutch ECMV disconnection .1120
Failure code [DXHAKB] Left steering clutch ECMV short circuit .1122
Failure code [DXHAKY] Left steering clutch ECMV hot short .1124
Failure code [DXHBKA] Right brake ECMV disconnection 1126
Failure code [DXHBKB] Right brake ECMV short circuit 1128
Failure code [DXHBKY] Right brake ECMV hot short 1130
Failure code [DXHCKA] Left brake ECMV disconnection .1132
Failure code [DXHCKB] Left brake ECMV short circuit .1134
Failure code [DXHCKY] Left brake ECMV hot short .1136
Failure code [F@BBZL] (or VHMS LED display “n338”) Engine blow-by pressure abnormally high level 1138
Failure code [F@BYNR] (or VHMS LED display “n362”) Front exhaust temperature abnormally high level (2) 1140
Failure code [F@BYNS] (or VHMS LED display “n361”) Front exhaust temperature abnormally high level (1) 1142
Failure code [F@BZNR] (or VHMS LED display “n372”) Rear exhaust temperature abnormally high level (2) .1144
Failure code [F@BZNS] (or VHMS LED display “n371”) Rear exhaust temperature abnormally high level (1) .1146
Troubleshooting of electrical system (E-mode) .1149
Information in troubleshooting table 1151
E-1 The engine does not start .1152
E-2 Preheat does not operate (Manual preheating function) .1157
E-3 The ripper pin puller cylinder does not operate .1160
E-4 When the starting switch is ON, none of the machine monitor come on .1162
E-5 When the starting switch is turned ON, the machine monitor completely remains lighted and does not go out .1164
E-6 When the starting switch is ON, the basic check item flashes 1166
E-7 While the engine is operating, any caution item flashes .1168
E-8 An emergency caution item flashes while the engine is running .1171
E-9 While the preheater is operating, the preheating pilot lamp does not come on 1176
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine) 1178
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on 1178
E-12 The engine coolant temperature gauge does not indicate normally 1179
E-13 Indication of the power train (torque converter) temperature gauge is abnormal .1180
E-14 The hydraulic oil temperature gauge does not indicate normally .1182
E-15 Indication of the fuel gauge is abnormal .1183
E-16 Indications of gear speed and engine speed are abnormal 1184
E-17 Indication of the shift mode service meter is abnormal .1184
E-18 The switch module cannot be operated .1185
E-19 The warning lamp does not flash or does not go out .1186
E-20 The alarm buzzer does not sound or does not stop .1187
E-21 Auto shift down is not possible or is not released .1188
E-22 The alarm buzzer cannot be cancelled .1189
E-23 The operator mode cannot be operated .1190
E-24 The service mode cannot be operated 1192
E-25 The back-up alarm does not sound .1194
E-26 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on 1196
E-27 Air conditioner does not operate .1202
E-28 Orbcomm terminal does not operate normally (Data are not transmitted) 1206
E-29 Fan does not reverse .1208
E-30 Gear cannot be shifted .1210
E-31 Electric priming pump does not operate or does not stop automatically 1212
Troubleshooting of hydraulic and mechanical system (H-mode) .1215
Information in troubleshooting table 1217
H-1 No force (no drawbar pull) 1218
H-2 No travel (at 2nd or 3rd speed) .1220
H-3 No travel at all gear speeds 1222
H-4 Machine travels only in one direction forward or in reverse .1224
H-5 Large time lag at gear speed shifting or forward-reverse shifting .1225
H-6 Steering is not possible 1226
H-7 Steering is possible only on one side .1227
H-8 Steering overrun occurs .1228
H-9 Brake does not work .1229
H-10 Torque converter is not lock-up 1230
H-11 Power train oil overheats 1231
H-12 All work equipment operates slowly .1232
H-13 All work equipment does not operate 1233
H-14 Blade lift speed is slow or lacks power 1234
H-15 Blade tilt speed is slow or lacks power 1234
H-16 Ripper lift speed is slow or lacks power .1235
H-17 Ripper tilt speed is slow or lacks power .1235
H-18 Excessive hydraulic drift of blade lift 1236
H-19 Excessive hydraulic drift of blade tilt 1237
H-20 Excessive hydraulic drift of ripper lift .1238
H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine) .1239
H-22 Blade pitch does not work (dual tilt attachment machine) .1240
H-23 Abnormal sound comes out from around work equipment pump .1241
H-24 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats) .1242
Troubleshooting of engine (S-mode) 1245
Method of using troubleshooting chart .1247
S-1 Engine does not start easily 1250
S-2 Engine does not start .1252
S-3 Engine does not pick up smoothly (follow-up is poor) 1256
S-4 Engine stops during operation .1257
S-5 Engine does not rotate smoothly (hunting) .1258
S-6 Engine lacks output (or lacks power) 1259
S-7 Exhaust smoke is black (Incomplete combustion) 1261
S-8 Oil is consumed much (or exhaust gas color is blue) .1263
S-9 Engine oil becomes contaminated quickly .1264
S-10 Fuel consumption is excessive 1265
S-11 Coolant contains oil (blows back or reduces) .1266
S-12 Oil pressure lamp lights up (drop in oil pressure) .1267
S-13 Oil level rises (Water, fuel in oil) .1268
S-14 Coolant temperature rises too high (Overheating) .1270
S-15 Abnormal noise is made .1271
S-16 Vibration is excessive .1272
S-17 Air cannot be bled from fuel circuit .1274
50 Disassembly and assembly . 0
General information on disassembly and assembly .1277
How to read this manual .1278
Coating materials list 1280
Special tool list .1283
Sketchs of special tools 1293
Engine and cooling system .1303
Removal and installation of engine assembly .1304
Removal and installation of cooling assembly (radiator, aftercooler and hydraulic oil cooler) .1309
Removal and installation of radiator 1312
Removal and installation of hydraulic oil cooler 1314
Removal and installation of aftercooler .1315
Removal and installation of radiator guard assembly .1316
Removal and installation of fuel tank assembly 1320
Removal and installation of engine hood assembly 1321
Removal and installation of fan drive assembly 1323
Removal and installation of fan motor assembly 1325
Engine 1329
Removal and installation of fuel supply pump assembly .1330
Removal and installation of cylinder head assembly 1334
Removal and installation of fuel injector assembly 1350
Removal and installation of engine front seal .1355
Removal and installation of engine rear seal 1357
Power train, Part 1 .1363
Removal and installation of damper assembly .1364
Disassembly and assembly of damper 1368
Removal and installation of power train unit assembly .1371
Disconnection and connection of power train unit assembly .1375
Disassembly and assembly of PTO assembly 1381
Disassembly and assembly of torque converter assembly .1387
Disassembly and assembly of torqflow transmission assembly 1396
Power train, Part 2 .1421
Disassembly and assembly of steering case assembly 1422
Removal and installation of power train, lubrication pump assembly 1437
Removal and installation of scavenging pump assembly 1438
Removal and installation of final drive assembly 1439
Disassembly and assembly of final drive assembly 1440
Undercarriage and frame, Part 1 .1455
Removal and installation of track frame assembly 1456
Removal and installation of idler assembly 1461
Disassembly and assembly of idler assembly 1462
Removal and installation of recoil spring assembly 1465
Disassembly and assembly of recoil spring assembly 1480
Removal and installation track roller assembly 1482
Disassembly and assembly of track roller assembly .1485
Removal and installation of carrier roller assembly .1487
Disassembly and assembly of carrier roller assembly .1488
Removal and installation of bogie assembly 1491
Disassembly and assembly of bogie assembly 1496
Removal and installation of 1st bogie assembly 1498
Undercarriage and frame, Part 2 .1505
Expansion and installation of track shoe assembly .1506
Whole disassembly and assembly of track shoe 1509
Dimensions table of fitting jig of link press .1526
Disassembly and assembly of 1 link in the field .1527
Disassembly and assembly of master link .1531
Removal and installation of pivot shaft assembly 1536
Removal and installation of equalizer bar .1537
Disassembly and assembly of equalizer bar bushing .1540
Removal and installation of segment tooth .1542
Hydraulic system 1545
Removal and installation of hydraulic tank and control valve assembly .1546
Removal and installation of work equipment pump assembly 1549
Removal and installation of fan pump assembly .1551
Removal and installation of control valve assembly 1554
Assembly of control valve assembly 1556
Disassembly and assembly of PPC charge valve assembly .1562
Disassembly and assembly of blade PPC valve assembly 1563
Disassembly and assembly of ripper PPC valve assembly .1565
Disassembly and assembly of hydraulic cylinder assembly .1566
Disassembly and assembly of ripper pin puller cylinder assembly .1571
Work equipment 1575
Removal and installation of blade assembly 1576
Disassembly and assembly of blade assembly 1578
Disassembly and assembly of giant ripper assembly .1582
Cab and its attachments .1587
Removal and installation of ROPS guard 1588
Removal and installation of operator’s cab assembly .1589
Removal and installation of floor frame assembly 1593
Electrical system .1599
Removal and installation of transmission and steering controller assembly .1600
Removal and installation of engine controller assembly 1601
Removal and installation of VHMS controller assembly 1603
Removal and installation of air conditioner unit assembly .1604
Removal and installation of monitor panel assembly 1607
90 Diagrams and drawings 0
Hydraulic diagrams and drawings .1609
Hydraulic circuit diagram (1/2) .1611
Hydraulic circuit diagram (2/2) .1613
Power train hydraulic circuit diagram .1615
Electrical diagrams and drawings 1619
Electrical circuit diagram (1/13) .1621
Electrical circuit diagram (2/13) .1623
Electrical circuit diagram (3/13) .1625
Electrical circuit diagram (4/13) .1627
Electrical circuit diagram (5/13) .1629
Electrical circuit diagram (6/13) .1631
Electrical circuit diagram (7/13) .1633
Electrical circuit diagram (8/13) .1635
Electrical circuit diagram (9/13) .1637
Electrical circuit diagram (10/13) 1639
Electrical circuit diagram (11/13) 1641
Electrical circuit diagram (12/13) 1643
Electrical circuit diagram (13/13) 1645
Electrical circuit diagram for inside cab .1647
Air conditioner unit electrical circuit diagram .1649
Connectors table and arrangement drawing 1651

DESCRIPTION:

Komatsu Bulldozer D375A-5E0 Shop Manual SEN00986-15 –  PDF DOWNLOAD

• SERIAL NUMBERS 50001 and up

G.B 26/12/24