Komatsu Bulldozer D375A-5R Shop Manual SEN02424-09 PDF DOWNLOAD

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Komatsu Bulldozer D375A-5R Shop Manual SEN02424-09 PDF DOWNLOAD

FILE DETAILS:

Komatsu Bulldozer D375A-5R Shop Manual SEN02424-09 PDF DOWNLOAD

Language : English
Pages : 490
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu Bulldozer D375A-5R Shop Manual SEN02424-09 PDF DOWNLOAD

• SERIAL NUMBERS 55001 and up

Cover . 1
00 Index and foreword . 0
Index . 3
Composition of shop manual 4
Table of contents . 6
Foreword and general information 19
Safety notice . 20
How to read the shop manual . 25
Explanation of terms for maintenance standard . 27
Handling of electric equipment and hydraulic component 29
Handling of connectors newly used for engines . 38
How to read electric wire code 41
Precautions when carrying out operation . 44
Method of disassembling and connecting push-pull type coupler . 47
Standard tightening torque table 50
Conversion table 54
01 Specification 0
Specification and technical data 61
Specification drawing . 62
Specifications 63
Weight table 68
Table of fuel, coolant and lubricants . 70
10 Structure, function and maintenance standard . 0
Engine and cooling system . 73
Engine mount 74
Cooling system 76
Cooling fan pump 78
Cooling fan motor . 94
Power train, Part 1 . 103
Power train . 104
Overall drawing of power train unit . 106
Power train hydraulic piping drawing 108
Damper, universal joint . 110
Torque converter, PTO . 112
Scavenging pump . 119
Torque converter valve 120
Power train, Part 2 . 133
Transmission control 134
Transmission 140
Transmission ECMV . 154
Transmission lubrication relief valve . 160
Power train pump + lubrication pump . 161
Steering, brake control . 162
Transfer, bevel gear shaft, steering 164
Steering ECMV . 174
Steering clutch ECMV, Steering brake ECMV . 178
Parking brake valve . 185
Sudden stop prevention valve 186
Final drive . 187
Sprocket 192
Undercarriage and frame . 195
Track frame . 196
Recoil spring . 200
Idler . 204
Track roller 206
Carrier roller 208
Track roller bogie 209
Track shoe 212
Main frame 214
Suspension 217
Hydraulic system, Part 1 223
Work equipment hydraulic piping diagram . 224
PPC control piping diagram 228
Work equipment control 230
Hydraulic tank 232
Accumulator . 234
PPC lock valve 235
PPC valve . 236
Hydraulic cylinder 250
Piston valve 254
Quick drop valve 255
Pin puller switch . 257
Pin puller solenoid valve . 258
Blade control knob 260
Pitch, dual tilt solenoid valve . 261
Work equipment pump . 264
Hydraulic system, Part 2 267
Control valve . 268
Self pressure reducing valve 300
Work equipment 309
Cylinder stay . 310
Blade . 312
Cutting edge, end bit . 316
Ripper 318
Cab and its attachments . 321
Cab mount . 322
Cab . 323
Air conditioner . 325
Electrical system . 327
Engine control system . 328
CRI engine control system . 336
Monitor system 338
Machine monitor . 340
Mode selection system . 350
Electrical equipment 354
Palm command control system . 356
Sensors . 358
Vehicle health monitoring system (VHMS) . 362
ORBCOMM terminal system . 368
20 Standard value table . 0
Standard service value table 373
Standard value table for engine . 374
Standard value table for machine 375
30 Testing and adjusting 0
Testing and adjusting, Part 1 . 385
Tools for testing, adjusting, and troubleshooting . 387
Testing engine speed 390
Testing intake air pressure (boostpressure) . 392
Testing exhaust temperature . 394
Testing exhaust gas color . 396
Adjusting valve clearance . 398
Testing compression pressure 400
Testing blow-by pressure 403
Testing engine oil pressure . 404
Handling of fuel system devices . 405
Releasing residual pressure fromfuel system . 405
Testing fuel pressure . 406
Handling of reduced cylindermode operation 407
Handling of no injection crankingoperation 407
Testing leakage from pressure limiter and return rate from injector . 408
Bleeding air from fuel circuit 411
Testing fuel circuit for leakage 413
Handling controller voltage circuit . 414
Replacing and adjusting alternator and air conditioner compressor belt 414
Testing fan motor speed . 415
Testing fan circuit oil pressure 417
Bleeding air from fan pump 418
Adjusting fuel control dial and decelerator pedal . 419
Testing and adjusting, Part 2 . 423
Testing power train oil pressure 425
Adjusting transmission speedsensor 435
Simple procedure for testing brake performance 436
Adjusting brake pedal and parking brake lever . 438
Adjusting position of pccs lever console 441
Emergency escape method when there is failure in power train 442
Inspecting wear of sprocket . 444
Testing and adjusting track shoe tension 445
Testing work equipment oil pressure . 446
Testing control circuit main pressure . 448
Testing PPC valve output pressure . 449
Adjusting play of PPC valve . 451
Testing output pressure of ripper pin-puller solenoid valve . 452
Checking location of cause of hydraulic drift of blade and ripper . 453
Testing leakage inside work equipment cylinder 454
Releasing remaining pressure in work equipment cylinders 455
Bleeding air from work equipment cylinders 455
Adjusting ripper lever position . 456
Adjusting work equipment lock lever . 457
Testing and adjusting operator’s cab 458
Adjusting blade . 462
Testing and adjusting, Part 3 . 465
Special functions of monitor panel (EMMS) . 466
Testing and adjusting, Part 4 . 517
Adjustment method when controller has been replaced . 518
Preparation work for troubleshooting for electrical equipment system 520
Inspection procedure of diode . 523
Handling of optional devices 524
Request for opening ORBCOMM terminal 525
Initialization procedures for VHMS controller . 527
Using method of KOMTRAX functions of ORBCOMM terminal . 549
Precautions for replacing VHMS controller . 552
Pm Clinic service . 558
40 Troubleshooting 0
Failure code table and fuse locations . 573
Failure codes table . 574
Fuse locations 584
General information on troubleshooting 589
Points to remember when troubleshooting . 590
Sequence of events in troubleshooting . 591
Check before troubleshooting 592
Classification and procedures for troubleshooting . 593
Information in troubleshooting table 596
Connection table for connector pin numbers 598
T-branch box and T- branch adapter table 634
Troubleshooting by failure code, Part 1 . 639
Failure code [1380MW] Lockup clutch slip 641
Failure code [1500L0] Transmission clutch 2 system abnormality 642
Failure code [15E0MW] Transmission clutch slip 643
Failure code [15SAL1] When forward clutch oil pressure command current is OFF, fill signal is ON 644
Failure code [15SALH] When forward clutch oil pressure command current is ON, fill signal is OFF 646
Failure code [15SBL1] When reverse clutch oil pressure command current is OFF, fill signal is ON 648
Failure code [15SBLH] When reverse clutch oil pressure command current is ON, fill signal is OFF 650
Failure code [15SEL1] When 1st clutch oil pressure command current is OFF, fill signal is ON 652
Failure code [15SELH] When 1st clutch oil pressure command current is ON, fill signal is OFF 654
Failure code [15SFL1] When 2nd clutch oil pressure command current is OFF, fill signal is ON 656
Failure code [15SFLH] When 2nd clutch oil pressure command current is ON, fill signal is OFF 658
Failure code [15SGL1] When 3rd clutch oil pressure command current is OFF, fill signal is ON 660
Failure code [15SGLH] When 3rd clutch oil pressure command current is ON, fill signal is OFF 662
Failure code [1800MW] Power train clutch slip . 664
Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON . 666
Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF . 668
Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON 670
Failure code [2202LH] When left steering clutch oil pressure command current is ON, fill signal is OFF 672
Failure code [2300NR] Brake thermal load abnormality 674
Failure code [2301L1] When right steering brake oil pressure command current is OFF, fill signal is ON 676
Failure code [2301LH] When right steering brake oil pressure command current is ON, fill signal is OFF 678
Failure code [2301NR] Right steering brake thermal load abnormality . 680
Failure code [2302L1] When left steering brake oil pressure command current is OFF, fill signal is ON . 682
Failure code [2302LH] When left steering brake oil pressure command current is ON, fill signal is OFF . 684
Failure code [2302NR] Left steering brake thermal load abnormality 686
Failure code [6001ZK] Failure code for design . 686
Failure code [A000NS] Engine overheat . 687
Failure code [AA10NX] Air cleaner clogging 688
Failure code [AB00MA] Alternator malfunction 689
Failure code [B@BAZG] Engine oil pressure reduction . 690
Failure code [B@BAZK] Engine oil level reduction 691
Failure code [B@BCNS] Engine coolant overheat . 692
Failure code [B@BCZK] Engine coolant level reduction 693
Failure code [B@BEBF] Water in engine fuel 694
Failure code [B@BFZK] Fuel level reduction 695
Failure code [B@CENS] Power train oil overheat 696
Failure code [B@CHZG] HSS charge oil pressure reduction . 697
Failure code [B@CHZK] Power train oil level reduction . 697
Failure code [B@GAZK] Battery electrolyte level reduction . 698
Failure code [B@HANS] Hydraulic oil overheat 698
Failure code [B@HAZK] Hydraulic oil level reduction . 699
Troubleshooting by failure code, Part 2 . 701
Failure code [CA111] Engine controller internal abnormality . 704
Failure code [CA115] Engine Ne/Bkup speed sensor abnormality 706
Failure code [CA122] Charge pressure sensor abnormally high level . 708
Failure code [CA123] Charge pressure sensor abnormally low level 710
Failure code [CA131] Throttle sensor abnormally high level 712
Failure code [CA132] Throttle sensor abnormally low level . 714
Failure code [CA135] Engine oil pressure sensor abnormally high level . 716
Failure code [CA141] Engine oil pressure sensor abnormally low level 718
Failure code [CA144] Coolant temperature sensor abnormally high level . 720
Failure code [CA145] Coolant temperature sensor abnormally low level 722
Failure code [CA153] Charge temperature sensor abnormally high level 724
Failure code [CA154] Charge temperature sensor abnormally low level . 726
Failure code [CA187] Sensor power supply 2 abnormally low level . 727
Failure code [CA212] Engine oil temperature sensor abnormally high level 728
Failure code [CA213] Engine oil temperature sensor abnormally low level . 730
Failure code [CA221] Ambient pressure sensor abnormally high level 732
Failure code [CA222] Ambient pressure sensor abnormally low level . 734
Failure code [CA227] Sensor power supply 2 abnormally high level 736
Failure code [CA234] Engine overspeed . 738
Failure code [CA238] Ne speed sensor power supply abnormality . 740
Failure code [CA263] Fuel temperature sensor abnormally high level 742
Failure code [CA265] Fuel temperature sensor abnormally low level . 744
Failure code [CA271] PCV1 short circuit . 746
Failure code [CA272] PCV1 disconnection . 748
Failure code [CA273] PCV2 short circuit . 750
Failure code [CA274] PCV2 disconnection . 752
Failure code [CA322] Injector #1 system disconnection or short circuit 754
Failure code [CA323] Injector #5 system disconnection or short circuit 756
Failure code [CA324] Injector #3 system disconnection or short circuit 758
Failure code [CA325] Injector #6 system disconnection or short circuit 760
Failure code [CA331] Injector #2 system disconnection or short circuit 762
Failure code [CA332] Injector #4 system disconnection or short circuit 764
Failure code [CA342] Engine controller data mismatch 766
Failure code [CA351] Injector drive circuit abnormality . 768
Failure code [CA352] Sensor power supply 1 abnormally low level . 770
Failure code [CA386] Sensor power supply 1 abnormally high level 772
Failure code [CA441] Power supply voltage abnormally low level 774
Failure code [CA442] Power supply voltage abnormally high level . 774
Failure code [CA449] Common rail pressure abnormally high pressure 2 775
Failure code [CA451] Common rail pressure sensor abnormally highlevel . 776
Failure code [CA452] Common rail pressure sensor abnormally lowlevel 778
Failure code [CA553] Common rail pressure abnormally high pressure 1 779
Failure code [CA554] Common rail pressure sensor in-range abnormality . 780
Failure code [CA559] Supply pump low pressure 1 . 781
Failure code [CA689] Engine Ne speed sensor abnormality . 786
Failure code [CA731] Engine Bkup speed sensor phase abnormality . 788
Failure code [CA757] Engine controller all data loss 789
Failure code [CA778] Engine Bkup speed sensor abnormality . 790
Troubleshooting by failure code, Part 3 . 793
Failure code [CA1633] CAN communication error (Engine controller) . 796
Failure code [CA2185] Throttle sensor power supply abnormally high level 798
Failure code [CA2186] Throttle sensor power supply abnormally low level . 800
Failure code [CA2249] Supply pump low pressure 2 801
Failure code [D110KA] Battery relay hold line disconnection . 802
Failure code [D110KB] Battery relay hold line short circuit . 804
Failure code [D130KA] Neutral safety relay disconnection 806
Failure code [D130KB] Neutral safety relay short circuit 808
Failure code [D161KA] Backup alarm relay disconnection 810
Failure code [D161KB] Backup alarm relay short circuit 812
Failure code [D182KZ] Preheater relay disconnection or short circuit 814
Failure code [D190KA] Engine controller ACC signal cut relay disconnection 816
Failure code [D190KB] Engine controller ACC signal cut relay short circuit 818
Failure code [D5ZRKA] Snap shot switch disconnection 820
Failure code [D5ZRKB] Snap shot switch short circuit 821
Failure code [DAFRKR] Machine monitor CAN communication error . 822
Failure code [daFRKR] Machine monitor CAN communication error . 824
Failure code [dAFRKR] Machine monitor CAN communication error . 826
Failure code [DAQ0KT] Transmission controller internal abnormality 828
Failure code [DAQ1KK] Transmission controller main power supply voltage reduction . 830
Failure code [DAQ2KK] Transmission controller load power supply voltage reduction . 832
Failure code [DAQ5KK] Transmission controller sensor 5V power supply (1) voltage reduction 834
Failure code [DAQ6KK] Transmission controller sensor 24V power supply voltage reduction . 836
Failure code [DAQ7KK] Transmission controller sensor 5V power supply (2) voltage reduction 838
Failure code [DAQ9KQ] Transmission controller model selection signal disagreement . 840
Failure code [DAQRKR] Transmission controller CAN communication error . 842
Failure code [DAQSKR] Transmission controller S-NET communication error . 844
Troubleshooting by failure code, Part 4 . 847
Failure code [DB2RKR] Engine controller CAN communication error . 850
Failure code [dB2RKR] Engine controller CAN communication error . 852
Failure code [DB30KT] Steering controller internal abnormality 854
Failure code [DB31KK] Steering controller main power supply voltage reduction . 856
Failure code [DB32KK] Steering controller load power supply voltage reduction . 858
Failure code [DB35KK] Steering controller sensor 5V power supply (1) voltage reduction 860
Failure code [DB36KK] Steering controller sensor 24V power supply voltage reduction . 862
Failure code [DB37KK] Steering controller sensor 5V power supply (2) voltage reduction 864
Failure code [DB39KQ] Steering controller model selection signal disagreement . 866
Failure code [dB3RKR] Steering controller CAN communication error . 868
Failure code [DB3SKR] Steering controller S-NET communication error . 870
Failure code [DBB0KK] (or VHMS LED display “n901”) VHMS supply voltage abnormality 872
Failure code [DBB0KQ] (or VHMS LED display “nF11”) VHMS connector connection abnormality 874
Failure code [DBB3KK] (or VHMS LED display “n905”) VHMS controller battery direct power supply voltage reduction 876
Failure code [DBB5KP] (or VHMS LED display “n904”) Sensor power supply (5V) system abnormality 878
Failure code [DBB6KP] (or VHMS LED display “n902”) Sensor power supply (24V) system disconnection or short circuit 880
Failure code [DBB7KP] (or VHMS LED display “n903”) Sensor power supply (12V) system disconnection or short circuit 882
Failure code [DBBQKR] (or VHMS LED display “n802”) CAN communication error (VHMS controller) 884
Failure code [dbBRKR] VHMS controller CAN communication error . 888
Failure code [DD12KA] Shift-up switch disconnection . 890
Failure code [DD12KB] Shift-up switch short circuit . 892
Failure code [DD13KA] Shift-down switch disconnection . 894
Failure code [DD13KB] Shift-down switch short circuit . 896
Failure code [DD14KA] Parking brake lever switch disconnection 898
Failure code [DD14KB] Parking brake lever switch short circuit 900
Failure code [DDB9L4] Reverse switch disagreement . 902
Failure code [DDK3L4] Forward switch signal disagreement 904
Troubleshooting by failure code, Part 5 . 907
Failure code [DDK5KA] Shift switch disconnection 910
Failure code [DDK5KB] Shift switch short circuit 912
Failure code [DDN2LD] Blade tilt right oil pressure switch is held down for long time . 914
Failure code [DDN3LD] Blade tilt left oil pressure switch is held down for long time 916
Failure code [DDN7KA] Blade pitch switch disconnection 918
Failure code [DDN7KB] Blade pitch switch short circuit 920
Failure code [DDN9KA] Blade tilt switch disconnection . 922
Failure code [DDN9KB] Blade tilt switch short circuit . 924
Failure code [DDNALD] Blade lift raise oil pressure switch is held down for long time . 926
Failure code [DDNBLD] Ripper lift raise oil pressure switch is held down for long time 928
Failure code [DDNCLD] Ripper lift lower oil pressure switch is held down for long time 930
Failure code [DDNDLD] Ripper tilt in oil pressure switch is held down for long time . 932
Failure code [DDNELD] Ripper tilt back oil pressure switch is held down for long time . 934
Failure code [DDNFLD] Blade lift lower oil pressure switch is held down for long time . 936
Failure code [DDQ2KA] Parking brake lever switch disconnection 938
Failure code [DDQ2KB] Parking brake lever switch short circuit 940
Failure code [DDQ2L4] Parking brake lever switch ON/OFF signal disagreement . 942
Failure code [dDQ2L4] Parking brake lever switch ON/OFF signal disagreement . 943
Failure code [DDT5KA] Neutral switch disconnection 944
Failure code [DDT5KB] Neutral switch short circuit 946
Failure code [DDT5KQ] Lever specification selection signal disagreement . 948
Failure code [DGE5KX] (or VHMS LED display “n40”) Ambient temperature sensor system disconnection or short circuit 950
Failure code [DGS1KX] Hydraulic oil temperature sensor signal out of range 952
Failure code [DGT1KA] Power train oil temperature sensor disconnection 954
Failure code [DGT1KX] Power train oil temperature sensor input signal out of range 956
Failure code [DGT5KA] (or VHMS LED display “n322”) Front exhaust temperature sensor system short circuit 958
Failure code [DGT5KB] (or VHMS LED display “n321”) Front exhaust temperature sensor system disconnection 960
Failure code [DGT6KA] (or VHMS LED display “n312”) Rear exhaust temperature sensor system short circuit . 962
Failure code [DGT6KB] (or VHMS LED display “n311”) Rear exhaust temperature sensor system disconnection . 964
Failure code [DH22KA] Work equipment pump oil pressure sensor 1 disconnection . 966
Failure code [DH22KB] Work equipment pump oil pressure sensor 1 short circuit . 968
Failure code [DH23KA] Work equipment pump oil pressure sensor 2 disconnection . 970
Failure code [DH23KB] Work equipment pump oil pressure sensor 2 short circuit . 972
Failure code [DHE5KB] (or VHMS LED display “n332”) Engine blow-by pressure sensor system disconnection 974
Failure code [DHE5KY] (or VHMS LED display “n331”) Engine blow-by pressure sensor system short circuit 976
Failure code [DHT3KX] (or VHMS LED display “n614”) Transmission oil pressure sensor input signal out of range . 978
Failure code [DK10KA] Fuel control dial disconnection . 980
Failure code [DK10KB] Fuel control dial short circuit . 982
Troubleshooting by failure code, Part 6 . 985
Failure code [DK30KA] Steering potentiometer 1 disconnection 988
Failure code [DK30KB] Steering potentiometer 1 short circuit 990
Failure code [DK30KX] Steering potentiometer 1 input signal out of range 992
Failure code [DK30KZ] Steering potentiometer 1 disconnection or short circuit . 993
Failure code [DK30L8] Steering potentiometer 1 analog signal disagreement . 994
Failure code [DK31KA] Steering potentiometer 2 disconnection 996
Failure code [DK31KB] Steering potentiometer 2 short circuit 998
Failure code [DK40KA] Brake potentiometer disconnection .1000
Failure code [DK40KB] Brake potentiometer short circuit .1002
Failure code [DK55KX] Direction potentiometer input signal out of range .1004
Failure code [DK55KZ] Direction potentiometer disconnection or short circuit 1005
Failure code [DK55L8] Direction potentiometer analog signal disagreement 1006
Failure code [DK56KA] Direction potentiometer 1 disconnection .1008
Failure code [DK56KB] Direction potentiometer 1 short circuit .1010
Failure code [DK57KA] Direction potentiometer 2 disconnection .1012
Failure code [DK57KB] Direction potentiometer 2 short circuit .1014
Failure code [DK60KA] Acceleration sensor disconnection .1016
Failure code [DK60KB] Acceleration sensor short circuit .1018
Failure code [DKH1KA] Pitch angle sensor disconnection 1020
Failure code [DKH1KB] Pitch angle sensor short circuit 1022
Failure code [DKH1KX] Pitch angle sensor input signal out of range 1023
Failure code [DLF1KA] Torque converter output speed sensor disconnection 1024
Failure code [DLT3KA] Transmission output speed sensor disconnection 1 1025
Failure code [dLT3KA] Transmission output speed sensor disconnection 2 1026
Failure code [DLT3KB] Transmission output speed sensor short circuit1 .1027
Failure code [DV00KB] Alarm buzzer short circuit 1028
Failure code [DW59KA] Blade dual selector solenoid disconnection 1029
Failure code [DW59KB] Blade dual selector solenoid short circuit 1030
Failure code [DW59KY] Blade dual selector solenoid hot short 1031
Failure code [DW5AKA] Blade pitch selector solenoid disconnection .1032
Failure code [DW5AKB] Blade pitch selector solenoid short circuit .1033
Failure code [DW5AKY] Blade pitch selector solenoid hot short .1034
Failure code [DW7BKA] Fan reverse solenoid disconnection 1035
Failure code [DW7BKB] Fan reverse solenoid short circuit 1036
Failure code [DW7BKY] Fan reverse solenoid hot short 1037
Failure code [DWN3KA] Sudden stop prevention solenoid disconnection .1038
Failure code [DWN3KB] Sudden stop prevention solenoid short circuit .1040
Failure code [DWN3KY] Sudden stop prevention solenoid hot short .1042
Failure code [DWN5KA] Fan pulley solenoid 1 disconnection .1044
Failure code [DWN5KB] Fan pulley solenoid 1 short circuit .1046
Failure code [DWN5KY] Fan pulley solenoid 1 hot short .1048
Failure code [DWNCKA] Fan pulley solenoid 2 disconnection .1050
Failure code [DWNCKB] Fan pulley solenoid 2 short circuit .1052
Failure code [DWNCKY] Fan pulley solenoid 2 hot short .1054
Troubleshooting by failure code, Part 7 .1057
Failure code [DXH1KA] Lockup solenoid disconnection .1060
Failure code [DXH1KB] Lockup solenoid short circuit .1062
Failure code [DXH1KY] Lockup solenoid hot short .1064
Failure code [DXH4KA] 1st clutch ECMV disconnection .1066
Failure code [DXH4KB] 1st clutch ECMV short circuit .1068
Failure code [DXH4KY] 1st clutch ECMV hot short .1070
Failure code [DXH5KA] 2nd clutch ECMV disconnection .1072
Failure code [DXH5KB] 2nd clutch ECMV short circuit .1074
Failure code [DXH5KY] 2nd clutch ECMV hot short .1076
Failure code [DXH6KA] 3rd clutch ECMV disconnection .1078
Failure code [DXH6KB] 3rd clutch ECMV short circuit .1080
Failure code [DXH6KY] 3rd clutch ECMV hot short .1082
Failure code [DXH7KA] Reverse clutch ECMV disconnection .1084
Failure code [DXH7KB] Reverse clutch ECMV short circuit .1086
Failure code [DXH7KY] Reverse clutch ECMV hot short .1088
Failure code [DXH8KA] Forward clutch ECMV hot short .1090
Failure code [DXH8KB] Forward clutch ECMV short circuit .1092
Failure code [DXH8KY] Forward clutch ECMV hot short .1094
Failure code [DXH9KA] Right steering clutch ECMV disconnection 1096
Failure code [DXH9KB] Right steering clutch ECMV short circuit 1098
Failure code [DXH9KY] Right steering clutch ECMV hot short 1100
Failure code [DXHAKA] Left steering clutch ECMV disconnection .1102
Failure code [DXHAKB] Left steering clutch ECMV short circuit .1104
Failure code [DXHAKY] Left steering clutch ECMV hot short .1106
Failure code [DXHBKA] Right brake ECMV disconnection 1108
Failure code [DXHBKB] Right brake ECMV short circuit 1110
Failure code [DXHBKY] Right brake ECMV hot short 1112
Failure code [DXHCKA] Left brake ECMV disconnection .1114
Failure code [DXHCKB] Left brake ECMV short circuit .1116
Failure code [DXHCKY] Left brake ECMV hot short .1118
Failure code [F@BBZL] (or VHMS LED display “n338”) Engine blow-by pressure abnormally high level 1120
Failure code [F@BYNR] (or VHMS LED display “n362”) Front exhaust temperature abnormally high level (2) 1122
Failure code [F@BYNS] (or VHMS LED display “n361”) Front exhaust temperature abnormally high level (1) 1124
Failure code [F@BZNR] (or VHMS LED display “n372”) Rear exhaust temperature abnormally high level (2) .1126
Failure code [F@BZNS] (or VHMS LED display “n371”) Rear exhaust temperature abnormally high level (1) .1128
Troubleshooting of electrical system (E-mode) .1131
Information in troubleshooting table 1133
E-1 The engine does not start .1134
E-2 Preheat does not operate (Manual preheating function) .1139
E-3 The ripper pin puller cylinder does not operate .1142
E-4 When the starting switch is ON, none of the machine monitor come on .1144
E-5 When the starting switch is turned ON, the machine monitor completely remains lighted and does not go out .1146
E-6 When the starting switch is ON, the basic check item flashes 1148
E-7 While the engine is operating, any caution item flashes .1150
E-8 An emergency caution item flashes while the engine is running .1153
E-9 While the preheater is operating, the preheating pilot lamp does not come on 1156
E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine) 1158
E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on 1158
E-12 The engine coolant temperature gauge does not indicate normally 1159
E-13 Indication of the power train (torque converter) temperature gauge is abnormal .1160
E-14 The hydraulic oil temperature gauge does not indicate normally .1162
E-15 Indication of the fuel gauge is abnormal .1163
E-16 Indications of gear speed and engine speed are abnormal 1164
E-17 Indication of the shift mode service meter is abnormal .1164
E-18 The switch module cannot be operated .1165
E-19 The warning lamp does not flash or does not go out .1166
E-20 The alarm buzzer does not sound or does not stop .1167
E-21 Auto shift down is not possible or is not released .1168
E-22 The alarm buzzer cannot be cancelled .1169
E-23 The operator mode cannot be operated .1170
E-24 The service mode cannot be operated 1172
E-25 The back-up alarm does not sound .1174
E-26 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on 1176
E-27 Air conditioner does not operate .1182
E-28 Orbcomm terminal does not operate normally (Data are not transmitted) 1186
E-29 Fan does not reverse .1188
E-30 Gear cannot be shifted .1190
E-31 Electric priming pump does not operate or does not stop automatically 1192
Troubleshooting of hydraulic, mechanical system (H-mode) .1195
Information in troubleshooting table 1197
H-1 No force (no drawbar pull) 1198
H-2 No travel (at 2nd or 3rd speed) .1200
H-3 No travel at all gear speeds 1202
H-4 Machine travels only in one direction forward or in reverse .1204
H-5 Large time lag at gear speed shifting or forward-reverse shifting .1205
H-6 Steering is not possible 1206
H-7 Steering is possible only on one side .1207
H-8 Steering overrun occurs .1208
H-9 Brake does not work .1209
H-10 Torque converter is not lock-up 1210
H-11 Power train oil overheats 1211
H-12 All work equipment operates slowly .1212
H-13 All work equipment does not operate 1213
H-14 Blade lift speed is slow or lacks power 1214
H-15 Blade tilt speed is slow or lacks power 1214
H-16 Ripper lift speed is slow or lacks power .1215
H-17 Ripper tilt speed is slow or lacks power .1215
H-18 Excessive hydraulic drift of blade lift 1216
H-19 Excessive hydraulic drift of blade tilt 1217
H-20 Excessive hydraulic drift of ripper lift .1218
H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine) .1219
H-22 Blade pitch does not work (dual tilt attachment machine) .1220
H-23 Abnormal sound comes out from around work equipment pump .1221
H-24 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats) .1222
Troubleshooting of engine (S-mode) 1225
Method of using troubleshooting chart .1227
S-1 Starting performance of engine is poor 1230
S-2 Engine does not start .1231
S-3 Engine does not pick up smoothly 1234
S-4 Engine stops during operation .1235
S-5 Engine does not rotate smoothly .1236
S-6 Engine lack output (or lacks power) .1237
S-7 Exhaust gas is black (incomplete combustion) 1238
S-8 Oil consumption is excessive (or exhaust gas is blue) .1240
S-9 Oil becomes dirty quickly .1241
S-10 Fuel consumption is excessive 1242
S-11 Oil is in coolant (or coolant spurts back or coolant level goes down) 1243
S-12 Oil pressure drops .1244
S-13 Oil level rises (Entry of coolant or fuel) .1245
S-14 Coolant temperature becomes too high (overheating) .1246
S-15 Abnormal noise is made .1247
S-16 Vibration is excessive .1248
S-17 Air cannot be bled from fuel circuit .1250
50 Disassembly and assembly . 0
General information on disassembly and assembly .1253
How to read this manual .1254
Coating materials list 1256
Special tool list .1259
Sketchs of special tools 1269
Engine and cooling system (SAA6D170E-5) .1279
Removal and installation of engine assembly .1280
Removal and installation of radiator assembly (with aftercooler and hydraulic oil cooler) .1286
Removal and installation of radiator unit .1290
Removal and installation of hydraulic oil cooler assembly .1292
Removal and installation of aftercooler assembly 1293
Removal and installation of radiator guard assembly .1294
Removal and installation of fuel tank assembly 1299
Removal and installation of engine hood assembly 1300
Removal and installation of fan drive assembly 1302
Removal and installation of fan motor assembly 1304
Engine (SAA6D170E-5) 1307
Removal and installation of fuel supply pump assembly .1308
Removal and installation of cylinder head assembly 1313
Removal and installation of fuel injector assembly 1329
Removal and installation of engine front seal .1334
Removal and installation of engine rear seal 1336
Power train, Part 1 (Damper, power train, PTO, T/C, T/M) 1341
Removal and installation of damper assembly .1342
Disassembly and assembly of damper 1346
Removal and installation of power train unit assembly .1349
Disconnection of power train unit assembly 1353
Connection of power train unit assembly .1357
Disassembly and assembly of PTO assembly 1359
Disassembly and assembly of torque converter assembly .1365
Disassembly and assembly of torqflow transmission assembly 1374
Power train, Part 2 (Steering case, pump for power train, final drive) 1399
Disassembly and assembly of steering case assembly 1400
Removal and installation of power train, lubrication pump assembly 1415
Removal and installation of scavenging pump assembly 1416
Removal and installation of final drive assembly 1417
Disassembly and assembly of final drive assembly 1418
Undercarriage and frame, Part 1 (Track frame, idler, track roller, bogie) .1431
Removal and installation of track frame assembly 1432
Removal and installation of idler assembly 1438
Disassembly and assembly of idler assembly 1439
Removal and installation of recoil spring assembly 1442
Disassembly and assembly of recoil spring assembly 1447
Removal and installation track roller assembly 1449
Disassembly and assembly of track roller assembly .1454
Removal and installation of bogie assembly 1456
Disassembly and assembly of bogie assembly 1462
Removal and installation of 1st bogie assembly 1464
Undercarriage and frame, Part 2 (Track shoe, pivot shaft, equalizer bar) 1471
Expansion and installation of track shoe assembly .1472
Whole disassembly and assembly of track shoe 1475
Dimensions table of fitting jig of link press .1492
Disassembly and assembly of 1 link in the field .1493
Disassembly and assembly of master link .1497
Removal and installation of pivot shaft assembly 1502
Removal and installation of equalizer bar .1503
Disassembly and assembly of equalizer bar bushing .1506
Removal and installation of segment tooth .1508
Hydraulic system 1511
Removal and installation of hydraulic tank and control valve assembly .1512
Removal and installation of work equipment pump assembly 1515
Removal and installation of fan pump assembly .1517
Removal and installation of control valve assembly 1520
Assembly of control valve assembly 1522
Assembly of blade PPC valve assembly 1528
Disassembly and assembly of ripper PPC valve assembly .1530
Disassembly and assembly of hydraulic cylinder assembly .1531
Disassembly and assembly of ripper pin puller cylinder assembly .1536
Work equipment 1541
Removal and installation of blade assembly 1542
Disassembly and assembly of blade assembly 1544
Disassembly and assembly of giant ripper assembly .1548
Cab and its attachments .1553
Removal and installation of ROPS guard 1554
Removal and installation of operator’s cab assembly .1555
Removal and installation of floor frame assembly 1559
Electrical system .1565
Removal and installation of transmission and steering controller assembly .1566
Removal and installation of engine controller assembly 1567
Removal and installation of VHMS controller assembly 1569
Removal and installation of air conditioner unit assembly .1570
Removal and installation of monitor panel assembly 1573
90 Diagrams and drawings 0
Hydraulic diagrams and drawings .1575
Hydraulic circuit diagram (1/2) .1577
Hydraulic circuit diagram (2/2) .1578
Power train hydraulic circuit diagram .1579
Electrical diagrams and drawings 1582
Electrical circuit diagram (1/13) .1584
Electrical circuit diagram (2/13) .1585
Electrical circuit diagram (3/13) .1586
Electrical circuit diagram (4/13) .1587
Electrical circuit diagram (5/13) .1588
Electrical circuit diagram (6/13) .1589
Electrical circuit diagram (7/13) .1590
Electrical circuit diagram (8/13) .1591
Electrical circuit diagram (9/13) .1592
Electrical circuit diagram (10/13) 1593
Electrical circuit diagram (11/13) 1594
Electrical circuit diagram (12/13) 1595
Electrical circuit diagram (13/13) 1596
Electrical circuit diagram for inside cab .1597
Air conditioner unit electrical circuit diagram .1598
Connectors table and arrangement drawing 1600

DESCRIPTION:

Komatsu Bulldozer D375A-5R Shop Manual SEN02424-09 PDF DOWNLOAD

G.B 26/12/24