Komatsu BULLDOZER D375A-6 Shop Manual SEN06849-01 PDF

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Komatsu BULLDOZER D375A-6 Shop Manual SEN06849-01 – PDF DOWNLOAD

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Komatsu BULLDOZER D375A-6 Shop Manual SEN06849-01 – PDF DOWNLOAD

Language : English
Pages :1736
Downloadable : Yes
File Type : PDF

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Komatsu BULLDOZER D375A-6 Shop Manual SEN06849-01 – PDF DOWNLOAD

SERIAL NUMBERS 60631 and up

Foreword and general information
Safety notice
D375A-6 Important safety notice

Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The shop manuals describe the effective and safe servicing and repair methods recommended by Komatsu. Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes. The symbol mark “k” is indicated for matters that require special precautions for such work. The work indicated with the warning mark should be carried out along to the instructions with special attention to the precautions. Should a hazardous situation occur or be anticipated during such work, be sure to proceed it safe and take every necessary measure.

1. General precautions 

Inappropriate handling creates an extreme danger. Read and understand what is described in the Operation and Maintenance Manual before operating the machine. Read and understand what is described in this manual before starting work.

TABLE OF CONTENTS:

Komatsu BULLDOZER D375A-6 Shop Manual SEN06849-01 – PDF DOWNLOAD

SERIAL NUMBERS 60631 and up

Cover 1
00 Index and foreword 3
Table of contents 4
Forword and general information 15
Safety notice 15
How to read the shop manual 20
Explanation of terms for maintenance standard 22
Handling of electric equipment and hydraulic components 24
Handling of connectors newly used for engines 33
How to read electric wire code 36
Precautions when carrying out work 39
Method of disassembling and connecting push-pull type coupler 42
Standard tightening torque table 45
List of Abbreviation 49
Conversion table 53
01 Specification 59
Contents 60
Specification and technical data 61
Specification drawing 61
Specifications 62
Weight table 67
Table of fuel, coolant and lubricants 69
10 Structure and function 71
Contents 72
Engine and cooling system 74
Cooling system 74
Cooling fan pump 76
Cooling fan motor 96
Power train 102
Power train 102
Overall drawing of power train unit 104
Power train hydraulic equipment arrangement drawing 106
Damper and universal joint 108
Torque converter and PTO 110
Torque converter control valve 116
Main relief valve and torque converter relief valve 118
Lockup clutch ECMV and stator clutch ECMV 120
Scavenging pump 125
Transmission control 126
PCCS lever 128
Transmission 132
Transmission ECMV 146
Transmission lubrication relief valve 151
Steering and brake control 152
Transfer unit, bevel gear shaft and steering 154
Steering control valve 160
Steering clutch ECMV and Steering brake ECMV 162
Parking brake valve 170
Sudden stop prevention valve 171
Final drive 173
Undercarriage and frame 178
Track frame 178
Idler cushion 180
Track roller bogie 181
Main frame 182
Suspension 184
Hydraulic system 187
Work equipment hydraulic piping diagram 187
PPC control piping diagram 191
Work equipment control 192
Hydraulic tank 194
Accumulator 196
PPC lock valve 197
PPC valve 199
Piston valve 210
Quick drop valve 211
Pin puller switch 212
Pin puller solenoid valve 213
Blade control lever (only for the machine with dual tilt specification) 215
Work equipment pump 216
Control valve 228
Self-pressure reducing valve 252
Work equipment 259
Cylinder stay 259
Cab 260
Cab mount 260
Cab 261
Electrical system 264
Engine control 264
Engine control system 265
CRI engine control system 274
Monitor system 276
Machine monitor 278
Lamp system 296
Engine preheat (electrical intake air heater) control 297
Palm command control system 298
Sensor 301
Vehicle health monitoring system (VHMS) 308
Electric warming and preheating system 314
Pre-lubrication system 326
20 Standard value table 331
Contents 332
Standard service value table 333
Standard value table for engine 333
Standard value table for machine 334
30 Testing and adjusting 343
Contents 344
Tools for testing, adjusting and troubleshooting 346
Diagnosis equipment list 346
Engine and cooling system 348
Testing engine speed 348
Testing intake air pressure (boost pressure) 351
Testing exhaust temperature 353
Testing exhaust gas color 356
Adjusting valve clearance 358
Measuring compression pressure 360
Testing blow-by pressure 363
Testing engine oil pressure 365
Testing EGR valve drive oil pressure 366
Handling of fuel system devices 368
Releasing residual pressure from fuel system 369
Testing fuel pressure 370
Handling of reduced cylinder mode operation 371
Handling of no injection cranking operation 371
Testing leakage from pressure limiter and return rate from injector 372
Bleeding air from fuel circuit 375
Testing fuel circuit for leakage 377
Replacing and adjusting alternator and air conditioner compressor belt 378
Measuring fan speed 379
Testing fan circuit oil pressure 380
Bleeding air from fan pump 381
Adjusting fuel control dial and decelerator pedal 382
Power train 384
Testing power train oil pressure 384
Adjusting transmission output speed sensor 400
Simple test procedure for brake performance 401
Adjusting brake pedal and parking brake lever 402
Adjusting position of pccs lever console 405
Emergency escape method when there is failure in power train 406
Undercarriage and frame 408
Inspecting wear of sprocket 408
Testing and adjusting track shoe tension 409
Hydraulic system 410
Testing and adjusting work equipment oil pressure 410
Testing control circuit main pressure 413
Testing PPC valve output pressure 414
Adjusting play of PPC valve 416
Testing output pressure of ripper pin-puller solenoid valve 417
Checking location of cause of hydraulic drift of blade and ripper 418
Testing leakage inside work equipment cylinder 419
Releasing remaining pressure in work equipment cylinders 420
Bleeding air from work equipment cylinders 420
Adjusting ripper lever position 421
Work equipment 422
Adjusting work equipment lock lever 422
Adjusting blade 423
Cab and its attachments 425
Testing and adjusting operator’s cab 425
Testing and adjusting operator’s seat isolator 430
Electrical system 434
Special functions of machine monitor (EMMS) 434
Handling of voltage circuit of engine controller 495
Adjustment method when controller has been replaced 496
Preparation work for troubleshooting for electrical equipment system 500
Inspection procedure of diode 504
Handling of optional devices 505
Request for opening ORBCOMM terminal 506
Initialization procedures for VHMS controller 508
Using method of KOMTRAX functions of ORBCOMM terminal 523
Precautions for replacing VHMS controller 526
Pm Clinic 532
Pm Clinic service 532
40 Troubleshooting 543
Table of contents 544
General information on troubleshooting 551
Points to remember when troubleshooting 551
Sequence of events in troubleshooting 552
Checks before troubleshooting 553
Classification and procedures for troubleshooting 578
Failure codes table 581
Classification and procedures for troubleshooting numbers 587
Information in troubleshooting table 589
Troubleshooting method for disconnecting wiring harness of pressure sensor system 591
Connection table for connector pin numbers 594
T-branch box and T-branch adapter table 630
Connector list and layout 633
Fuse locations table 647
Troubleshooting by failurecode 651
Failure code [1380MW] Lock up clutch: Slip 651
Failure code [1500L0] Transmission clutch: Abnormal 652
Failure code [15E0MW] Transmission clutch: Slip 653
Failure code [15SAL1] Forward clutch: Fill high 654
Failure code [15SALH] Forward clutch: Fill Low 656
Failure code [15SBL1] Reverse clutch: Fill high 658
Failure code [15SBLH] Reverse clutch: Fill Low 660
Failure code [15SEL1] Speed 1st clutch: Fill high 662
Failure code [15SELH] Speed 1st clutch: Fill Low 664
Failure code [15SFL1] Speed 2nd clutch: Fill high 666
Failure code [15SFLH] Speed 2nd clutch: Fill Low 668
Failure code [15SGL1] Speed 3rd clutch: Fill high 670
Failure code [15SGLH] Speed 3rd clutch: Fill Low 672
Failure code [15SJL1] L/U: Fill high 674
Failure code [15SJLH] L/U: Fill low 676
Failure code [1800MW] P/T clutch: Slip 678
Failure code [2201L1] Right clutch: Fill high 680
Failure code [2201LH] Right clutch: Fill low 682
Failure code [2202L1] Left clutch: Fill high 684
Failure code [2202LH] Left clutch: Fill low 686
Failure code [2300NR] Brake Themal Load Abnormality 688
Failure code [2301L1] Right brake: Fill high 690
Failure code [2301LH] Right brake: Fill low 692
Failure code [2301NR] Steering Brake RH Themal Load Abnormality 694
Failure code [2302L1] Left brake: Fill high 696
Failure code [2302LH] Left brake: Fill low 698
Failure code [2302NR] Steering Brake LH Themal Load Abnormality 700
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection 702
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit 704
Failure code [AA10NX] Air Cleaner Clogging 706
Failure code [AB00MA] Battery Charge Abnormal 708
Failure code [B@BAZG] Eng Oil Press Low 709
Failure code [B@BAZK] Eng Oil Level Low 710
Failure code [B@BCNS] Eng Water Overheat 711
Failure code [B@BCZK] Eng Water Level Low 711
Failure code [B@CENS] T/C Oil Overheat 712
Failure code [B@HANS] Hyd Oil Overheat 713
Failure code [B@HAZK] Hyd Oil Level Low 714
Failure code [CA111] ECM Critical Internal Failure 716
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 718
Failure code [CA122] Chg Air Press Sensor High Error 720
Failure code [CA123] Chg Air Press Sensor Low Error 722
Failure code [CA131] Throttle Sensor High Error 724
Failure code [CA132] Throttle Sensor Low Error 726
Failure code [CA135] Eng Oil Press Sensor High Error 728
Failure code [CA141] Eng Oil Press Sensor Low Error 730
Failure code [CA144] Coolant Temp Sens High Error 732
Failure code [CA145] Coolant Temp Sens Low Error 734
Failure code [CA153] Chg Air Temp Sensor High Error 736
Failure code [CA154] Chg Air Temp Sensor Low Error 738
Failure code [CA187] Sens Supply 2 Volt Low Error 740
Failure code [CA212] Eng Oil Temp Sensor High Error 742
Failure code [CA213] Eng Oil Temp Sensor Low Error 744
Failure code [CA221] Ambient Press Sens High Error 746
Failure code [CA222] Ambient Press Sens Low Error 748
Failure code [CA227] Sens Supply 2 Volt High Error 750
Failure code [CA234] Eng Overspeed 751
Failure code [CA238] Ne Speed Sens Supply Volt Error 752
Failure code [CA263] Fuel Temp Sensor High Error 754
Failure code [CA265] Fuel Temp Sensor Low Error 756
Failure code [CA271] IMV/PCV1 Short Error 758
Failure code [CA272] IMV/PCV1 Open Error 759
Failure code [CA273] PCV2 Short Error 760
Failure code [CA274] PCV2 Open Error 761
Failure code [CA322] Inj #1 (L#1) Open/Short Error 762
Failure code [CA323] Inj #5 (L#5) Open/Short Error 764
Failure code [CA324] Inj #3 (L#3) Open/Short Error 766
Failure code [CA325] Inj #6 (L#6) Open/Short Error 768
Failure code [CA331] Inj #2 (L#2) Open/Short Error 770
Failure code [CA332] Inj #4 (L#4) Open/Short Error 772
Failure code [CA342] Calibration Code Incompatibility 774
Failure code [CA351] Injectors Drive Circuit Error 775
Failure code [CA352] Sens Supply 1 Volt Low Error 776
Failure code [CA386] Sens Supply 1 Volt High Error 778
Failure code [CA441] Battery Voltage Low Error 779
Failure code [CA442] Battery Voltage High Error 780
Failure code [CA449] Rail Press Very High Error 781
Failure code [CA451] Rail Press Sensor High Error 782
Failure code [CA452] Rail Press Sensor Low Error 784
Failure code [CA553] Rail Press High Error 786
Failure code [CA554] Rail Press Sensor In Range Error 787
Failure code [CA559] Rail Press Low Error 788
Failure code [CA689] Eng Ne Speed Sensor Error 792
Failure code [CA731] Eng Bkup Speed Sens Phase Error 794
Failure code [CA757] All Continuous Data Lost Error 795
Failure code [CA778] Eng Bkup Speed Sensor Error 796
Failure code [CA1228] EGR Valve Servo Error 1 798
Failure code [CA1625] EGR Valve Servo Error 2 799
Failure code [CA1633] KOMNET Datalink Timeout Error 800
Failure code [CA2185] Throt Sens Sup Volt High Error 801
Failure code [CA2186] Throt Sens Sup Volt Low Error 802
Failure code [CA2249] Rail Press Very Low Error 803
Failure code [CA2271] EGR Valve Pos Sens High Error 804
Failure code [CA2272] EGR Valve Pos Sens Low Error 806
Failure code [CA2351] EGR Valve Sol Current High Error 808
Failure code [CA2352] EGR Valve Sol Current Low Error 810
Failure code [D110KB] Battery Relay: Drive Short Circuit 812
Failure code [D130KA] Neutral relay: Disconnection 814
Failure code [D130KB] Neutral relay: Short circuit 816
Failure code [D161KA] Back-up alarm releay: Disconnection 818
Failure code [D161KB] Back-up alarm releay: Short circuit 820
Failure code [D182KZ] Preheater Relay Abnormality 822
Failure code [D190KA] ACC signal relay: Disconnection 824
Failure code [D190KB] ACC signal relay: Short circuit 826
Failure code [D1EFKA] Pre lub motor relay: Disconnection 828
Failure code [D1EFKB] Pre lub motor relay: Short circuit 830
Failure code [DAFRKR] Monitor: Can communication lost (PT) 832
Failure code [dAFRKR] Monitor: CAN communication lost (WE) 833
Failure code [DAFRMC] CAN Discon (Monitor Detected) 834
Failure code [DB2RKR] ENG cont: Can communication lost (PT) 839
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) 842
Failure code [DB90KT] WE controller: Abnormality in controller 843
Failure code [DB91KK] WE controller: Source voltage reduction 844
Failure code [DB92KK] WE controller: Output voltage reduction 846
Failure code [DB97KK] WE cont: Sensor voltage 5 V (2) reduction 848
Failure code [DB99KQ] WE controller: Type select signal 850
Failure code [DB9RKR] WE controller: Can communication lost (PT) 851
Failure code [DBB0KK] VHMS controller:Source voltage reduction 854
Failure code [DBB0KQ] VHMS connector connection abnormality 856
Failure code [DBB3KK] VHMS controller: Source voltage reduction 857
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction 860
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction 862
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction 864
Failure code [DBBQKR] PT cont: Can communication lost (VHMS) 865
Failure code [DBE0KT] PT controller: Abnormality in controller 865
Failure code [DBE1KK] PT controller: Source voltage reduction 866
Failure code [DBE2KK] PT controller: Output voltage reduction 868
Failure code [DBE5KK] PT cont: Sensor voltage 5 V (1) reduction 870
Failure code [DBE6KK] PT cont: Sensor voltage 24V reduction 872
Failure code [DBE7KK] PT cont: Sensor voltage 5 V reduction 874
Failure code [DBE9KQ] PT controller: Type select signal 876
Failure code [DBERKR] PT controller: Can communication lost (WE) 877
Failure code [DD12KA] Shift up Sw: Disconnection 880
Failure code [DD12KB] Shift up Sw: Short circuit 882
Failure code [DD13KA] Shift down Sw: Disconnection 884
Failure code [DD13KB] Shift down Sw: Short circuit 886
Failure code [DD14KA] Parking lever Sw: Dissconnection 888
Failure code [DD14KB] Parking lever Sw: Short circuit 890
Failure code [DDB9L4] Reverse SW Signal disagreement 892
Failure code [DDE2KA] Pre lub oil press sw: Disconnection 894
Failure code [DDK3L4] Forward SW Signal disagreement 896
Failure code [DDK5KA] Shift switch disconnection 898
Failure code [DDK5KB] Shift switch short circuit 900
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality 902
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality 904
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection 906
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit 908
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection 910
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit 912
Failure code [DDNALD] Blade lift up pressure SW abnormality 914
Failure code [DDNBLD] Ripper lift up pressure SW abnormality 916
Failure code [DDNCLD] Ripper lift down pressure SW abnormality 918
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality 920
Failure code [DDNELD] Ripper tilt back pressure SW abnormality 922
Failure code [DDNFLD] Blade lift down pressure SW abnormality 924
Failure code [DDNLKA] Weq lock Sw: Disconnection 926
Failure code [DDNLKB] Weq lock Sw: Short circuit 928
Failure code [DDT5KA] Neutral switch disconnection 930
Failure code [DDT5KB] Neutral switch short circuit 932
Failure code [DDT5KQ] Lever SPEC selection signal disagreement 934
Failure code [DDTSL1] S/C: Fill high 936
Failure code [DDTSLH] S/C: Fill low 938
Failure code [DGE5KX] Ambient temp sensor abnormality 940
Failure code [DGS1KX] Hyd oil temp: signal abnormal 942
Failure code [DGT1KA] T/C oil temp sensor: Abnormal 944
Failure code [DGT1KX] T/C oil temp sensor: Abnormal 946
Failure code [DGT5KA] F exhaust temp sensor disconnection 948
Failure code [DGT5KB] F exhaust temp sensor short circuit 950
Failure code [DGT6KA] R exhaust temp sensor disconnection 952
Failure code [DGT6KB] R exhaust temp sensor short circuit 954
Failure code [DH21KA] Weq pressure sensor: Disconnection 956
Failure code [DH21KB] Weq pressure sensor: Short circuit 958
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection 960
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit 962
Failure code [DHT3KX] T/M oil pressure sensor abnormality 964
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection 966
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit 968
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection 970
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit 972
Failure code [DK10KA] Fuel control Dial: Disconnection 974
Failure code [DK10KB] Fuel control Dial: Short circuit 976
Failure code [DK30KA] ST lever 1: Disconnection 978
Failure code [DK30KB] ST lever 1: Short circuit 980
Failure code [DK30KX] ST lever: Out of normal range 982
Failure code [DK30KZ] ST lever: Disconnection or short circuit 982
Failure code [DK30L8] ST lever: Signal mismatch 983
Failure code [DK31KA] ST lever 2: Disconnection 984
Failure code [DK31KB] ST lever 2: Short circuit 986
Failure code [DK40KA] Brake potentiometer: Disconnection 988
Failure code [DK40KB] Brake potentiometer: Short circuit 990
Failure code [DK55KX] FR lever: Out of normal range 992
Failure code [DK55KZ] FR lever: Disconnection or short circuit 992
Failure code [DK55L8] FR lever: Signal mismatch 993
Failure code [DK56KA] FR lever 1: Disconnection 994
Failure code [DK56KB] FR lever 1: Short circuit 996
Failure code [DK57KA] FR lever 2: Disconnection 998
Failure code [DK57KB] FR lever 2: Short circuit1000
Failure code [DK60KA] Acceleration sensor: Disconnection1002
Failure code [DK60KB] Acceleration sensor: Short circuit1004
Failure code [DKH1KA] Pitch angle sensor: Disconnection1006
Failure code [DKH1KB] Pitch angle sensor: Short circuit1008
Failure code [DLF1KA] T/C out-speed sensor: Disconnection1010
Failure code [DLM3KA] Fan rev sensor: Disconnection1011
Failure code [DLM3MB] Fan control: Decline1012
Failure code [DLT3KA] T/M out-speed sensor: Disconnection1013
Failure code [DLT3KB] T/M out-speed sensor: Abnormal1014
Failure code [DW59KA] Blade dual selector SOL disconnection1015
Failure code [DW59KB] Blade dual selector SOL short circuit1016
Failure code [DW59KY] Blade dual selector SOL hot short1017
Failure code [DW5AKA] Blade pitch selector SOL disconnection1018
Failure code [DW5AKB] Blade pitch selector SOL short circuit1019
Failure code [DW5AKY] Blade pitch selector SOL Short circuit1020
Failure code [DW7BKA] Fan rev EPC: Disconnection1021
Failure code [DW7BKB] Fan rev EPC: Short circuit1022
Failure code [DWN3KA] Ssp solenoid: Disconnection1023
Failure code [DWN3KB] Ssp solenoid: Short circuit1024
Failure code [DWN3KY] SSP solenoid: Short circuit1025
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection1027
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit1028
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit1029
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection1031
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit1032
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit1034
Failure code [DXH1KA] Lock-up ECMV: Disconnection1036
Failure code [DXH1KB] Lock-up ECMV: Short circuit1037
Failure code [DXH1KY] Lock-up ECMV: Short circuit1038
Failure code [DXH4KA] 1st clutch ECMV: Disconnection1040
Failure code [DXH4KB] 1st clutch ECMV: Short circuit1041
Failure code [DXH4KY] 1st clutch ECMV: Short circuit1042
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection1044
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit1045
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit1046
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection1048
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit1049
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit1050
Failure code [DXH7KA] R clutch ECMV: Disconnection1052
Failure code [DXH7KB] R clutch ECMV: Short circuit1053
Failure code [DXH7KY] R clutch ECMV: Short circuit1054
Failure code [DXH8KA] F clutch ECMV: Disconnection1056
Failure code [DXH8KB] F clutch ECMV: Short circuit1057
Failure code [DXH8KY] F clutch ECMV: Short circuit1058
Failure code [DXH9KA] Right clutch ECMV: Disconnection1060
Failure code [DXH9KB] Right clutch ECMV: Short circuit1061
Failure code [DXH9KY] Right clutch ECMV: Short circuit1062
Failure code [DXHAKA] Left clutch ECMV: Disconnection1064
Failure code [DXHAKB] Left clutch ECMV: Short circuit1065
Failure code [DXHAKY] Left clutch ECMV: Short circuit1066
Failure code [DXHBKA] Right brake ECMV: Disconnection1068
Failure code [DXHBKB] Right brake ECMV: Short circuit1069
Failure code [DXHBKY] Right brake ECMV: Short circuit1070
Failure code [DXHCKA] Left brake ECMV: Disconnection1072
Failure code [DXHCKB] Left brake ECMV: Short circuit1073
Failure code [DXHCKY] Left brake ECMV: Short circuit1074
Failure code [DXJBKA] S/C ECMV: Disconnection1076
Failure code [DXJBKB] S/C ECMV: Short circuit1077
Failure code [DXJBKY] S/C ECMV: Short circuit1078
Failure code [DY2HKA] Pre lub motor: Disconnection1080
Failure code [F@BBZL] ENG blow-by pressure high level1082
Failure code [F@BYNR] F exhaust temp high level (2)1083
Failure code [F@BYNS] F exhaust temp high level (1)1083
Failure code [F@BZNR] R exhaust temp high level (2)1084
Failure code [F@BZNS] R exhaust temp high level (1)1085
Troubleshooting of electrical system (E-mode)1086
Information contained in troubleshooting table1086
E-1 Engine does not start (starting motor does not turn)1089
E-2 Preheater does not operate1092
E-3 When starting switch is turned ON, machine monitor displays nothing1096
E-4 When starting switch is turned ON (before starting engine), basic check item lights up1098
E-5 Precaution item lights up while engine is running1100
E-6 Emergency stop item lights up while engine is running1102
E-7 Engine coolant temperature gauge does not indicate normally1103
E-8 Fuel gauge does not indicate properly1104
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally1106
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally1107
E-11 Contents of display by machine monitor are different from applicable machine1108
E-12 Machine monitor does not display some items1108
E-13 Function switch does not work1108
E-14 Operation mode does not change1109
E-15 Gearshift mode does not change1109
E-16 Customize function does not operate normally1110
E-17 Customize memory function does not operate normally1110
E-18 Alarm buzzer does not sound or does not stop1111
E-19 When starting switch is turned OFF, service meter is not displayed1111
E-20 Machine monitor cannot be set in service mode1111
E-21 The ripper pin puller cylinder does not operate1112
E-22 Horn does not sound or does not stop1114
E-23 Back-up alarm does not sound or does not stop1116
E-24 Fan does not reverse1118
E-25 The head lamp and rear lamp do not light up1119
E-26 Windshield wiper does not operate1126
E-27 Window washer does not operate1132
E-28 Electric priming pump does not operate or does not stop automatically1138
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)1140
E-30 Gear cannot be shifted1142
Troubleshooting of hydraulic and mechanical system (H-mode)1143
Information in troubleshooting table1143
List of Failure Modes and Causes1144
H-1 Machine lacks power(or drawbar pull)1146
H-2 Machine cannot travel (at 2nd or 3rd each speed)1148
H-3 Machine cannot travel at any gear speeds1149
H-4 Machine travels only in one direction, forward or reverse1151
H-5 Large time lag at gear shifting or directional change1152
H-6 Machine connot turn1153
H-7 Machine turns only to one side1154
H-8 Machine overruns at turnning1154
H-9 Brake does not work1155
H-10 Torque converter does not lock up1156
H-11 Power train oil overheats1157
H-12 All work equipment operates too slow or lacks power1158
H-13 All work equipment does not operate1159
H-14 Blade lift cylinder speed is too slow or lacks power1160
H-15 Blade tilt cylinder speed is too slow or lacks power1160
H-16 Ripper lift cylinder speed is too slow or lacks power1161
H-17 Ripper tilt cylinder speed is too slow or lacks power1161
H-18 Excessive hydraulic drift of blade lift cylinder1162
H-19 Excessive hydraulic drift of blade tilt cylinder1162
H-20 Excessive hydraulic drift of ripper lift cylinder1163
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper)1163
H-22 Blade pitch does not work (machine with dual tilt specification)1164
H-23 Abnormal noise from around work equipment pump1164
H-24 Abnormal fan rotation (noise and/or vibration are abnormally large or engine overheats)1165
H-25 Operator’s seat isolator quakes abnormally or makes shocks (Machine with operator’s seat isolator)1165
Troubleshooting of engine (S-mode)1166
Method of using troubleshooting chart1166
S-1 Engine does not start easily1170
S-2 Engine does not start1172
S-3 Engine does not rev up smoothly (response-up is poor)1176
S-4 Engine stops during operation1177
S-5 Engine does not rotate smoothly (hunting)1179
S-6 Engine lacks power (or output shortage)1180
S-7 Exhaust smoke is black (Incomplete combustion)1182
S-8 Oil is consumption is excessive(or exhaust smoke is blue)1184
S-9 Engine oil becomes contaminated quickly1185
S-10 Fuel consumption is excessive1186
S-11 Oil mixes into coolant(coolant blows back or is reduced)1187
S-12 Engine pressure monitor lights up (drop in engine oil pressure)1188
S-13 Oil level rises (Coolant or fuel mixes into oil)1189
S-14 Coolant temperature rises too high (overheating)1191
S-15 Abnormal noise is heard1192
S-16 Vibration is excessive1193
S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but stalls)1194
50 Disassembly and assembly1197
Contents1198
General information on disassembly and assembly1200
How to read this manual1200
Coating materials list1202
Special tools list1205
Sketches of special tools1212
Engine and cooling system1220
Removal and installation of fuel supply pump assembly1220
Removal and installation of fuel injector assembly1224
Removal and installation of cylinder head assembly1229
Removal and installation of radiator guard assembly1245
Removal and installation of cooling assembly (radiator, aftercooler, and hydraulic oil cooler)1250
Removal and installation of radiator1255
Removal and installation of hydraulic oil cooler1257
Removal and installation of aftercooler1258
Removal and installation of engine assembly1259
Removal and installation of engine hood assembly1266
Removal and installation of engine front seal1269
Removal and installation of engine rear seal1271
Removal and installation of fan drive assembly1275
Removal and installation of fan motor assembly1277
Removal and installation of fuel tank assembly1279
Removal and installation of combustion type preheater assembly1281
Power train1284
Removal and installation of damper assembly1284
Disassembly and assembly of damper assembly1288
Removal and installation of power train unit assembly1291
Disconnection and connection of power train unit assembly1298
Disassembly and assembly of PTO assembly1307
Disassembly and assembly of torque converter assembly1313
Disassembly and assembly of TORQFLOW transmission assembly1323
Disassembly and assembly of steering case assembly1351
Removal and installation of power train pump and lubrication pump assembly1367
Removal and installation of scavenging pump assembly1368
Removal and installation of final drive assembly1369
Disassembly and assembly of final drive assembly1371
Undercarriage and frame1384
Removal and installation of track frame assembly1384
Removal and installation of idler assembly1389
Disassembly and assembly of idler assembly1390
Remove and install recoil spring assembly1394
Disassembly and assembly of recoil spring assembly1409
Removal and installation of track roller assembly1411
Disassembly and assembly of track roller assembly1414
Removal and installation of carrier roller assembly1417
Disassembly and assembly of carrier roller assembly1418
Removal and installation of bogie assembly1422
Disassembly and assembly of bogie assembly1427
Removal and installation of first bogie assembly1429
Separation and connection of track shoe assembly1434
Overall disassembly and assembly of track shoe1438
Link press press-fitting jig dimensions1455
Disassembly and assembly of one link assembly in the field1456
Disassembly and assembly of master link1461
Removal and installation of pivot shaft assembly1465
Removal and installation of equalizer bar1466
Disassembly and assembly of equalizer bar bushing1470
Removal and installation of segment tooth1472
Hydraulic system1473
Removal and installation of hydraulic tank assembly1473
Removal and installation of work equipment pump assembly1476
Removal and installation of fan pump assembly1480
Removal and installation of control valve assembly1481
Disassembly and assembly of control valve assembly1483
Disassembly and assembly of blade PPC valve assembly1488
Disassembly and assembly of ripper PPC valve assembly1491
Disassembly and assembly of hydraulic cylinder assembly1493
Disassembly and assembly of ripper pin puller cylinder assembly1501
Work equipment1504
Removal and installation of blade assembly1504
Disassembly and assembly of blade assembly1506
Disassembly and assembly of giant ripper assembly1510
Cab and its attachments1513
Removal and installation of ROPS guard1513
Removal and installation of operator’ cab assembly1514
Removal and installation of floor frame assembly1518
Removal and installation of air conditioner unit assembly1523
Removal and installation of operator’s seat isolator1529
Disassembly and assembly of operator’s seat isolator1530
Electrical system1532
Removal and installation of transmission controller assembly and steering controller assembly1532
Removal and installation of engine controller assembly1533
Removal and installation of VHMS controller assembly1535
Removal and installation of machine monitor assembly1536
60 Maintenance standard1539
Table of contents1540
Engine and cooling system1541
Engine mount1541
Cooling fan pump1543
Cooling fan motor1550
Power train1552
Power train unit1552
Damper and universal joint1554
Torque converter and PTO1557
Main relief valve and torque converter relief valve1560
Lockup clutch ECMV and stator clutch ECMV1561
Scavenging pump1562
Transmission control1563
Transmission1564
Transmission lubricating oil relief valve1568
Power train and lubrication pump1569
Transfer, bevel gear shaft and steering unit1570
Steering control valve1576
Steering clutch ECMV and steering brake ECMV1577
Parking brake valve1578
Final drive1579
Sprocket1582
Undercarriage and frame1584
Track frame1584
Idler cushion1586
Idler1588
Track roller1590
Carrier roller1592
Track roller bogie1593
Track shoe1594
Main frame1598
Suspension1600
Hydraulic system1605
PPC valve1605
Hydraulic cylinder1610
Quick drop valve1613
Work equipment pump1614
Control valve1617
Self-pressure reducing valve1629
Work equipment1631
Cylinder stay1631
Blade1632
Cutting edge and end bit1636
Ripper1638
80 Appendix1639
Contents1640
CAB Heater1641
Heater component1641
Heater unit1646
Blower unit1648
FRESH/RECIRC air changeover damper1649
Heater control panel1650
Procedure for testing and troubleshooting1652
Circuit diagram and arrangement of connector pins1653
System diagram1655
Parts and connectors layout (CAB heater)1657
Testing temperature control1661
Testing FRESH/RECIRC air changeover1661
Testing relay1662
Troubleshooting chart 11664
Troubleshooting chart 21665
Information in troubleshooting table1666
Troubleshooting for power supply system (CAB heater does not operate)1668
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)1670
Troubleshooting for temperature control1676
Troubleshooting for FRESH/RECIRC air changeover1678
Additional heater does not operate1680
90 Diagrams and drawings1685
Contents1686
Hydraulic diagrams and drawings1687
Symbols used in hydraulic circuit diagrams1687
Power train hydraulic diagrams and drawings1689
Hydraulic circuit diagram1691
Electrical diagrams and drawings1695
Symbols used in electrical circuit diagrams1695
Electrical circuit diagram1699
Index1727

S.M 30/12/24