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KOMATSU D375A-5 SHOP MANUAL SEBM023511 – PDF DOWNLOAD
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Description
KOMATSU D375A-5 SHOP MANUAL SEBM023511 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D375A-5 SHOP MANUAL SEBM023511 – PDF DOWNLOAD
Language : English
Pages : 1044
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D375A-5 SHOP MANUAL SEBM023511 – PDF DOWNLOAD
COVER........................................................................................................ 1 CONTENTS..................................................................................................... 2 01 GENERAL................................................................................................... 27 SPECIFICATION DRAWING.................................................................................... 28 SPECIFICATIONS........................................................................................... 30 WEIGHT TABLE............................................................................................. 36 TABLE OF FUEL,COOLANT AND LUBRICANT...................................................................... 38 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD.............................................................. 39 POWER TRAIN.............................................................................................. 42 OVERALL DRAWING OF POWER TRAIN UNIT...................................................................... 44 POWER TRAIN HYDRAULIC PIPING DRAWING..................................................................... 46 DAMPER,UNIVERSAL JOINT................................................................................... 48 TORQUE CONVERTER,PTO..................................................................................... 50 TORQUE CONVERTER VALVE................................................................................... 58 SCAVENGING PUMP.......................................................................................... 69 TRANSMISSION CONTROL..................................................................................... 70 TRANSMISSION............................................................................................. 72 TRANSMISSION ECMV........................................................................................ 84 TRANSMISSION LUBRICATION RELIEF VALVE.................................................................... 90 POWER TRAIN PUMP+LUBRICATION PUMP........................................................................ 91 STEERING,BRAKE CONTROL................................................................................... 92 TRANSFER,BEVEL GEAR SHAFT,STEERING....................................................................... 95 STEERING ECMV............................................................................................ 102 STEERING CLUTCH,STEERING BRAKE ECMV...................................................................... 106 PARKING BRAKE VALVE...................................................................................... 113 SUDDEN STOPS PREVENTION VALVE............................................................................ 114 FINAL DRIVE.............................................................................................. 115 TRACK FRAME.............................................................................................. 120 RECOIL SPRING............................................................................................ 122 IDLER.................................................................................................... 124 TRACK ROLLER............................................................................................. 126 CARRIER ROLLER........................................................................................... 127 TRACK ROLLER BOGIE....................................................................................... 128 TRACK SHOE............................................................................................... 130 MAIN FRAME............................................................................................... 132 SUSPENSION............................................................................................... 134 WORK EQUIPMENT HUDRAULIC PIPING DIAGRAM.................................................................. 137 PPC CONTROL PIPING DIAGRAM............................................................................... 141 WORK EQUIPMENT CONTROL................................................................................... 142 HYDRAULIC TANK........................................................................................... 144 PPC CHARGE VALVE......................................................................................... 146 ACCUMULATOR.............................................................................................. 149 PPC LOCK VALVE........................................................................................... 150 PPC VALVE................................................................................................ 152 WORK EQUIPMENT CYLINDER.................................................................................. 164 PISTON VALVE............................................................................................. 167 QUICK DROP VALVE......................................................................................... 168 PIN PULLER SWITCH........................................................................................ 170 PIN PULLER SOLENOID VALVE................................................................................ 171 BLADE CONTROL KNOB....................................................................................... 173 PITCH, DUAL TILT SOLENOID VALVE.......................................................................... 174 WORK EQUIPMENT+PPC CHARGE PUMP........................................................................... 176 MAIN CONTROL VALVE....................................................................................... 178 CYLINDER STAY............................................................................................ 214 BLADE.................................................................................................... 216 RIPPER EQUIPMENT......................................................................................... 222 CAB MOUNT................................................................................................ 226 CAB...................................................................................................... 227 AIR CONDITIONER.......................................................................................... 229 ENGINE CONTROL........................................................................................... 230 ENGINE CONTROL SYSTEM.................................................................................... 231 DECELERATOR POTENTIOMETER................................................................................ 232 HPI ENGINE CONTROL SYSTEM................................................................................ 234 MONITOR SYSTEM........................................................................................... 236 MONITOR PANEL............................................................................................ 238 SENSORS.................................................................................................. 242 MODE SELECTION SYSTEM.................................................................................... 245 SENSORS.................................................................................................. 248 ELECTRICAL DEVICE........................................................................................ 251 STEERING ELECTRONIC CONTROL.............................................................................. 254 20 TESTING AND ADJUSTING..................................................................................... 257 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS............................................................ 258 STANDARD VALUE TABLE FOR MACHINE RELATED PARTS........................................................... 263 TESTING AND ADJUSTING.................................................................................... 271 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING..................................................... 272 MEASURING ENGINE SPEED............................................................................... 274 MEASURING INTAKE AIR PRESSURE(BOOST PRESSURE)........................................................ 276 MEASURING EXHAUST TEMPERATURE........................................................................ 277 MEASURING EXHAUST COLOR.............................................................................. 279 TROUBLESHOOTING FOR INJECTOR......................................................................... 282 ADJUSTING VALVE CLEARANCE............................................................................ 283 ADJUSTING INJECTOR SET LOAD.......................................................................... 284 MEASURING COMPRESSION PRESSURE....................................................................... 286 MEASURING BLOW-BY PRESSURE........................................................................... 288 MEASURING ENGINE OIL PRESSURE........................................................................ 289 HANDLING EQUIPMENT IN FUEL SYSTEM.................................................................... 290 MEASURING FUEL CIRCUIT PRESSURE...................................................................... 291 VISUAL INSPECTION OF RETURN FUEL..................................................................... 293 ARRANGEMENT OF CONTROL DEVICES FOR HPI............................................................... 294 BLEEDING AIR FROM FUEL CIRCUIT....................................................................... 296 ADJUSTING ENGINE SPEED SENSOR........................................................................ 298 REPLACING AND ADJUSTING FAN BELT..................................................................... 299 TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER COMPRESSOR BELT TENSION............................ 300 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL.................................................... 301 MEASURING POWER TRAIN OIL PRESSURE................................................................... 303 ADJUSTING TRANSMISSION SPEED SENSOR.................................................................. 314 SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE....................................................... 314 ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER ....................................................... 315 ADJUSTING POSITION OF PCCS LEVER CONSOLE............................................................. 319 EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER TRAIN......................................... 320 ADJUSTING IDLER CLEARANCE............................................................................ 322 CHECKING WEAR OF SPROCKET............................................................................ 322 TESTING AND ADJUSTING TRACK SHOE TENSION............................................................. 323 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE.................................................... 324 TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE.................................................. 329 MEASURING PPC VALVE OUTPUT PRESSURE.................................................................. 331 ADJUSTING PLAY OF PPC VALVE.......................................................................... 333 MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE........................................ 334 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER.................................... 335 MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER..................................................... 336 RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS............................................. 337 BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS........................................................... 337 ADJUSTING RIPPER LEVER POSITION...................................................................... 338 ADJUSTING SAFETY LOCK LEVER.......................................................................... 339 ADJUSTING BLADE...................................................................................... 340 ADJUSTMENT OF PCCS LEVER POTENTIOMETERS.............................................................. 342 CHECKING THE ADJUSTMENT OF PCCS LEVER................................................................ 344 DISASSEMBLY AND ASSEMBLY OF PCCS LEVER............................................................... 345 SPECIAL FUNCTIONS OF MONITOR PANEL(EMMS)............................................................. 348 PREPARATORY WORK WHEN TROUBLESHOOTING ELECTRICAL SYSTEM.............................................. 392 PM CLINIC SERVICE.................................................................................... 395 UNDERCARRIAGE TROUBLESHOOTING REPORT(NORMAL)......................................................... 403 UNDERCARRIAGE TROUBLESHOOTING REPORT(IMPACT)......................................................... 404 TROUBLESHOOTING.......................................................................................... 405 POINTS TO REMEMBER WHEN TROUBLESHOOTING.............................................................. 406 SEQUENCE OF EVENTS IN TROUBLESHOOTING................................................................ 407 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................... 408 CHECKS BEFORE TROUBLESHOOTING........................................................................ 416 CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING.................................................. 418 CONNECTOR ALLOCATION DRAWING DRAWING AND ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM ................ 421 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................... 440 T-BRANCH BOX AND T-BRANCH TABLE...................................................................... 463 TROUBLESHOOTING WHEN SERVICE CODE IS DISPLAYED(SERVICE CODE)......................................... 465 INFORMATION IN TROUBLESHOOTING TABLE............................................................ 468 SERVICE CODE[E0101][ABNORMALITY IN NETWORK SYSTEM(STEERING)]..................................... 470 SERVICE CODE[E0104][ABNORMALITY IN NETWORK SYSTEM(MONITOR PANEL)]................................ 472 SERVICE CODE[E0105][ABNORMALITY IN NETWORK SYSTEM(STEERING)]..................................... 474 SERVICE CODE[E0111](ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY SYSTEM)...................... 475 SERVICE CODE[E0112](ABNORMALITY IN TRANSMISSION CONTROOLER POWER SUPPLY SYSTEM).................. 477 SERVICE CODE[E0120](SHORT CIRCUIT IN CAUTION LAMP SYSTEM)........................................ 479 SERVICE CODE[E0121](SHORT CIRCUIT IN CAUTION BUZZER SYSTEM)...................................... 480 SERVICE CODE[E0142](ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER SUPPLY SYSTEM).............. 481 SERVICE CODE[E0143](ABNORMALITY IN STEERING CONTROLLER 5 V POWER SUPPLYS SYSTEM)................. 483 SERVICE CODE[E0145](ABNORMALITY IN STEERING CONROLLER 24 V POWER SUPPLY SYSTEM).................. 485 SERVICE CODE[E0146](ABNORMALITY IN TRANSMISSION ON CONTROLLER 24 V POWER SUPPLY SYSTEM).......... 486 SERVICE CODE[E0151](ABNORMALITY IN SELECTION OF STEERING CONTROLLER SPECIFICATION)............... 487 SERVICE CODE[E0152][ABNORMALITY IN NETWORK SYSTEM(STEERING)]..................................... 488 SERVICE CODE[E0160](ABNORMALITY IN TRANSMISSION CONTROLLER ROM).................................. 489 SERVICE CODE[E0161](ABNORMALITY IN STEERING CONTROLLER ROM)...................................... 489 SERVICE CODE[E0164][ABNORMALITY IN NETWORK SYSTEM(TRANSMISSION)]................................. 490 SERVICE CODE[E0176](DISCONNECTION IN BATTERY REPLAY SYSTEM)...................................... 492 SERVICE CODE[E0177](SHORT CIRCUIT IN BATTERY RELAY SYSTEM)....................................... 493 SERVICE CODE[E0178](DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)................................ 494 SERVICE CODE[E0179](SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)................................ 496 SERVICE CODE[E0211](ABNORMAL TORQUE CONVERTER OIL TEMPERATURE)................................... 498 SERVICE CODE[E0212](SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)................... 499 SERVICE CODE[E0213](DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)................... 500 SERVICE CODE[E0221](DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)................. 501 SERVICE CODE[E0225](SLIP OF POWER TRAIN CLUTCH).................................................. 503 SERVICE CODE[E0230][ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS(1)]................ 503 SERVICE CODE[E0231][ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS(2)]................ 504 SERVICE CODE[E0232] [ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS(3)]............... 504 SERVICE CODE[E0233](DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 1 SYSTEM).... 505 SERVICE CODE[E0234](DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 2 SYSTEM).... 507 SERVICE CODE[E0235](DEVIATION OF FORQARD-REVERSE POTENTIOMETER SYSTEM SIGNALS)................... 508 SERVICE CODE[E0236](DISCONNECTION OR SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS)................... 509 SERVICE CODE[E0237](DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS) ................ 511 SERVICE CODE[E0238](DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE LEVER SWITH SYSTEMS)......... 513 SERVICE CODE[E0239](DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)................... 515 SERVICE CODE[E0250](DISCONNECTION IN TRANSMISSION FORWARD CLUTCH ECMV(E-POCV)SYSTEM)............. 516 SERVICE CODE[E0251](SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH ECMV(E-POCV)SYSTEM)............. 517 SERVICE CODE[E0252](DISCONNECTION IN TRANSMISSION REVERSE CLUTCH ECMV(E-POCV)SYSTEM)............. 518 SERVICE CODE[E0253](SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV(E-POCV)SYSTEM)............. 519 SERVICE CODE[E0254](DISCONNECTION IN TRAINSMISSION 1ST CLUTCH ECMV(E-POCV)SYSTEM)................ 520 SERVICE CODE[E0255](SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV(E-POCV)SYSTEM)................. 521 SERVICE CODE[E0256](DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV(E-POCV)SYSTEM)................. 522 SERVICE CODE[E0257](SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV(E-POCV)SYSTEM)................. 523 SERVICE CODE[E0258](DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV(E-POCV)SYSTEM)................. 524 SERVICE CODE[E0259](SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV(E-POCV)SYSTEM)................. 525 SERVICE CODE[E0260](DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)......................... 526 SERVICE CODE[E0261](DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)...................... 527 SERVICE CODE[E0262](DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE CLUTH).......................... 528 SERVICE CODE[E0263](DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE CLUTCH)...................... 529 SERVICE CODE[E0264](DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH)............................. 530 SERVICE CODE[E0265](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST CLUTCH).......................... 531 SERVICE CODE[E0266](DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH)............................. 532 SERVICE CODE[E0267](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND CLUTCH).......................... 533 SERVICE CODE[E0268](DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH)............................. 534 SERVICE CODE[E0269](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD CLUTCH).......................... 535 SERVICE CODE[E0270][DOUBLE TROUBLE IN TRANSMISSION CLUTCH(DEFECTIVE ENGAGEMENT)]................. 536 SERVICE CODE[E0271][DOUBLE TROUBLE IN TRANSMISSION CLUTCH(DEFECTIVE DISENGAGEMENT)].............. 536 SERVICE CODE[E0306](SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM)................ 537 SERVICE CODE[E0307](SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM)................. 538 SERVICE CODE[E0308](SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE SWITCH SYSTEM)............... 539 SERVICE CODE[E0309](SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE SWITCH SYSTEM)............... 540 SERVICE CODE[E0310](SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH SYSTEM).................. 541 SERVICE CODE[E0311](DISCONNECTION OR SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS)................ 542 SERVICE CODE[E0312](DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS)................. 544 SERVICE CODE[E0321](DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID SYSTEM)........................ 546 SERVICE SODE[E0322](SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID SYSTEM) ....................... 547 SERVICE CODE[E0323](DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID SYSTEM)....................... 548 SERVICE SODE[E0324](SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID SYSTEM)....................... 549 SERVICE CODE[E0329](ABNORMAL HYDRAULIC OI TEMPERATURE)........................................... 550 SERVICE CODE[E0364](DISCONNECTION IN FRONT LARGE PUMP OIL PRESSURE SENSOR SYSTEM)................ 552 SERVICE CODE[E0365](SHORT CIRCUIT IN FRONT LARGE PUMP OIL PRESSURE SENSOR SYSTEM)................ 553 SERVICE CODE[E0366](DISCONNECTION IN CENTER SMALL PUMP OIL PRESSURE SENSOR SUSTEM)............... 554 SERVICE CODE[E0367](SHORT CIRCUIT IN CENTER SMALL PUMP OIL PRESSURE SENSOR SYSTEM) .............. 555 SERVICE CODE[E0405](DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM).................. 556 SERVICE CODE[E0430](ENGINE OIL:ABNORMAL OIL PRESSURE)............................................ 558 SERVICE CODE[E0431](ABNORMAL RADIATOR COOLANT LEVEL)............................................. 558 SERVICE CODE[E0432](RADIATOR COLLANT:OVERHEATING)................................................ 558 SERVICE CODE[E0486](ABNORMALITY IN SELECTION OF TRANSMISSION CONTROLLER SPECIFICATION)........... 560 SERVICE CODE[E0510](DISCONNECTION OR SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM)................ 561 SERVICE CODE[E0610](DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)................................. 562 SERVICE CODE[E0611](SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)................................. 564 SERVICE CODE[E0660](DISCONNECTION IN ACC SIGHAL DRIVE RELAY SYSTEM).............................. 566 SERVICE CODE[E0661](SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM).............................. 567 SERVICE CODE[E0721](DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)................. 568 SERVICE CODE[E0730][ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(1)]....................... 570 SERVICE CODE[E0731][ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(2)]....................... 570 SERVICE CODE[E0732][ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(3)]....................... 571 SERVICE CODE[E0733](DISCONNECTION OR SHORT CIRCUIT IN STEERING POTENTIOMETER 1 SYSTEM)........... 572 SERVICE CODE[E0734](DISCONNECTION OR SHORT CIRCUIT IN STEERING POTENTIOMETER 2 SYSTEM)........... 574 SERVICE CODE[E0735](DEVIATION OF STEERING POTENTIOMETER SYSTEM SIGNALS).......................... 575 SERVICE CODE[E0736](DISCONNECTION OR SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM)................ 576 SERVICE CODE[E0750](DISCONNECTION IN RIGHT STEERING CLUTCH ECMV(E-POCV)SYSTEM)................... 578 SERVICE CODE[E0751](SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV(E-POCV)SYSTEM)................... 579 SERVICE CODE[E0752](DISCONNECTION IN LEFT STEERING CLUTCH EXMV(E-POCV)SYSTEM).................... 580 SERVICE CODE[E0753](SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV(E-POCV)SYSTEM).................... 581 SERVICE CODE[E0754](DISCONNECTION IN RIGHT STEERING BRAKE ECMV(E-POCV)SYSTEM).................... 582 SERVICE CODE[E0755](SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV(E-POCV)SYSTEM).................... 583 SERVICE CODE[E0756](DISCONNECTION IN LEFT STEERING BRAKE ECMV(E-POCV)SYSTEM)..................... 584 SERVICE CODE[E0757](SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV(E-POCV)SYSTEM)..................... 585 SERVICE CODE[E0760](DEFECTIVE ENGAGEMENT OF RIGHT STEERING CLUTCH)............................... 586 SERVICE CODE[E0761](DEFECTIVE DISENGAGEMENT OF RIGHT STEERING CLUTCH)............................ 587 SERVICE CODE[E0762](DEFECTIVE ENGAGEMENT OF LEFT STEERING CLUTCH)................................ 588 SERVICE CODE[E0763](DEFECTIVE DISENGAGEMENT OF LEFT STEERING CLUTCH)............................. 589 SERVICE CODE[E0764](DEFECTIVE ENGAGEMENT OF RIGHT STEERING BRAKE)................................ 590 SERVICE CODE[E0765](DEFECTIVE DISENGAGEMENT OF RIGHT STEERING BRAKE)............................. 591 SERVICE CODE[E0766](DEFECTIVE ENGAGEMENT OF LEFT STEERING BRAKE)................................. 592 SERVICE CODE[E0767](DEFECTIVE DISENGAGEMENT OF LEFT STEERING BRAKE).............................. 593 SERVICE CODE[E0779](DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)..................... 594 SERVICE CODE[E0780](SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)..................... 595 SERVICE CODE[E0781](DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE LAVER SWITCH SYSTEMS)........ 596 SERVICE CODE[E0782](DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)................... 598 SERVICE CODE[E0930](DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)................................. 599 SERVICE CODE[E0931](DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)................................. 601 SERVICE CODE[E0932](DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)........................... 603 SERVICE CODE[E0933](DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)........................... 605 SERVICE CODE[E1939](ABNORMALITY IN J1939 COMMUNICATION SYSTEM)................................... 607 SERVICE CODE[EC111](ABNORMALITY IN ENGINE CONTROLLER MEMORY)..................................... 608 SERVICE CODE[EC112](ABNORMALITY IN TIMING RAIL ACTUATOR)......................................... 608 SERVICE CODE[EC113](ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM)............................. 609 SERVICE CODE[EC115](ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)................................ 610 SERVICE CODE[EC116](ABNORMALITY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)................ 612 SERVICE CODE[EC117](ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM).................. 613 SERVICE CODE[EC118](ABNORMALITY HIGH LEVEL IN PUEL PUMP PRESSURE SENSOR SYSTEM).................. 614 SERVICE CODE[EC119](ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM).................... 615 SERVICE CODE[EC121](ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS)................................ 615 SERVICE CODE[EC122](ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM)....................... 616 SERVICE CODE[EC123](ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM)........................ 617 SERVICE CODE[EC131](ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM)............................. 618 SERVICE CODE[EC132](ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM).............................. 619 SERVICE CODE[EC133](ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE SENSOR SYSTEM)...................... 620 SERVICE CODE[EC134](ABNORMALLY LOW LEVEL IN REMOTE SENSOR SYSTEM)................................ 621 SERVICE CODE[EC135](ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM).................. 622 SERVICE CODE[EC141](ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM)................... 623 SERVICE CODE[EC143](LOWERING OF ENGINE OIL PRESSURE)............................................. 623 SERVICE CODE[EC144](ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM)........... 624 SERVICE CODE[EC145](ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM)............ 625 SERVICE CODE[EC151](RISE OF ENGINE COOLANT TEMPERATURE).......................................... 625 SERVICE CODE[EC153](ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM)............... 626 SERVICE CODE[EC154](ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM)................ 627 SERVICE CODE[EC221](ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)................. 628 SERVICE CODE[EC222](ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM).................. 629 SERVICE CODE[EC234](OVER-SPEED).................................................................. 629 SERVICE CODE[EC254](ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)..................................... 630 SERVICE CODE[EC259](ABNORMALITY IN FUEL SHUT-OFF VALVE).......................................... 631 SERVICE CODE[EC261](ABNORMAL RISE OF FUEL TEMPERATURE)........................................... 631 SERVICE CODE[EC263](ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)..................... 632 SERVICE CODE[EC265](ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)...................... 633 SERVICE CODE[EC316](ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)...................................... 634 SERVICE CODE[EC318](ABNORMALITY IN FUEL PUMP ACTUATOR)........................................... 635 SERVICE CODE[EC346] (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER)........................ 636 SERVICE CODE[EC384](ABNORMALITY IN PREHEATER CONTROL SYSTEM)..................................... 638 SERVICE CODE[EC423](ABNORMALITY IN IN-PANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM)............... 640 SERVICE CODE[EC441](ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM) ............................. 642 SERVICE CODE[EC442](ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM)............................. 642 SERVICE CODE[EC451](ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM)................... 643 SERVICE CODE[EC452](ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM).................... 644 SERVICE CODE[EC455](ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)...................................... 645 SERVICE CODE[EC467](ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)................................. 646 SERVICE CODE[EC468](ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)................................... 646 SERVICE CODE[EC514](ABNORMALITY IN FUEL RAIL ACTUATOR)........................................... 647 SERVICE CODE[EC554](ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM)................. 648 TROUBLESHOOTING OF ELECTRICAL SYSTEM(E-MODE)......................................................... 651 INFORMATION IN TROUBLESHOOTING TABLE............................................................. 652 E-1 THE ENGINE DOES NOT START.................................................................... 653 E-2 PREHEAT DOES NOT OPERATE(MANUAL PREHEATING FUNCTION)......................................... 655 E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.............................................. 657 E-4 WHEN THE STARTING SWITCH IS ON, NONE OF THE MONITOR PANELS COME ON........................... 658 E-5 WHEN THE STARTING SWITCH IS ON, ALL MONITOR PANELS APE KEPT COMING ON AND DO NOT COME OUT.... 659 E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES................................. 660 E-7 WHEN THE ENGINE IS OPERATING,THE CAUTION ITEM FLASHES........................................ 661 E-8 WHEN THE ENGINE IS OPERATING,THE EMERGENCY ALARM ITEM FLASHES................................ 663 E-9 THE PREHEATING LAMP DOES NOT COME ON......................................................... 666 E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT NORMAL............................. 667 E-11 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT NORMAL..................... 668 E-12 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL................................................. 669 E-13 THE DISPLAY OF THE GEAR SPEED/ENGINE SPEED/SHIFT MODE IS NOT NORMAL........................ 670 E-14 THE DISPLAY OF THE SERVICE METER IS NOT MORMAL.............................................. 670 E-15 THE SWITCH MODULE CANNOT BE OPERATED........................................................ 672 E-16 THE ALARM LAMP DOES NOT FLASH OR COME OUT................................................... 673 E-17 THE ALARM BUZZER DOES NOT SOUND OR STOP..................................................... 674 E-18 THE ALARM BUZZER CANNOT BE CANCELLED........................................................ 675 E-19 THE SERVICE MODE CANNOT BE SELECTED......................................................... 676 E-20 BACK-UP ALAPM DOES NOT SOUND................................................................ 677 E-21 INSTRUMENT PANEL NIGHT LAMP,HEADLAMP,WORKING LAMP AND REAR LAMP DO NOT COME ON.............. 678 E-22 AIR CONDITIONER DOES NOT OPERATE............................................................ 682 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H-MODE)........................................... 685 INFORMATION IN TROUBLESHOOTING TABLE............................................................. 686 H-1 NO FORCE (NO DRAWBAR PULL)................................................................... 687 H-2 NO TRAVEL (AT 2ND OR 3RD SPEED).............................................................. 688 H-3 NO TRAVEL AT ALL GEAR SPEEDS................................................................. 689 H-4 LARGE LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING................................ 690 H-5 LARGE LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING................................. 691 H-6 STEERING IS NOT POSSIBLE..................................................................... 692 H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE........................................................ 692 H-8 STEERING OVERRUN OCCURS...................................................................... 693 H-9 BRAKE DOES NOT WORK.......................................................................... 693 H-10 TORQUE CONVERTER IS NOT LOCK-UP............................................................. 694 H-11 TORQUE CONVERTER OIL IS OVERHEATED.......................................................... 694 H-12 ALL WORK EQUIPMENT OPERATES SLOWLY.......................................................... 695 H-13 ALL WORK EQUIPMENT DOES NOT OPERATE......................................................... 696 H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER............................. 697 H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER............................. 697 H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER........................... 698 H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER................................. 698 H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE...................................................... 699 H-19 HYDRAULIC DRIFT OF BLADE TILT IS LARGE...................................................... 699 H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE..................................................... 700 H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE................................................. 700 H-22 BLADE PITCH DOES NOT OPERATE................................................................ 701 H-23 ABNORMAL NOISE OCCURS AROUND THE WORK EQUIPMENT PUMP........................................ 701 TROUBLESHOOTING OF THE ENGINE BODY(S-MODE)........................................................... 703 POINTS TO REMEMBER WHEN TROULESHOOTING........................................................... 704 METHOD OF USING TROUBLESHOOTING CHARTS........................................................... 705 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)..................................... 708 S-2 ENGINE DOES NOT START........................................................................ 711 1) ENGINE DOES NOT TURN...................................................................... 711 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).................. 712 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL ID BEING INJECTED)................. 714 S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR).......................................... 716 S-4 ENGINE STOPS DURING OPERATIONS............................................................... 718 S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)..................................................... 720 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)......................................................... 722 S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)................................................ 724 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)...................................... 726 S-9 OIL BECOMES CONTAMINATED QUICKLY............................................................. 727 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................... 728 S-11 OIL IS IN COOLING WATER ,OR WATER SPURTS BACK ,OR WATER LEVEL GOES DOWN..................... 729 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).................................. 730 S-13 OIL LEVEL RISES............................................................................. 731 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)............................................ 732 S-15 ABNORMAL NOISE IS MADE...................................................................... 733 S-16 VIBRATION IS EXCESSIVE...................................................................... 734 30 DISASSEMBLY AND ASSEMBLY.................................................................................. 735 HOW TO READ THIS MANUAL ................................................................................. 739 REMOVAL AND INSTALLATION OF ASSEMBLIES............................................................... 739 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES............................................................... 740 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................. 741 SPECIAL TOOL LIST........................................................................................ 743 SKETCHES OF SPECIAL TOOLS................................................................................ 752 REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY........................................................... 759 REMOVAL ............................................................................................. 759 INSTALLATION......................................................................................... 759 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL............................................................ 760 SPECIAL TOOLS........................................................................................ 760 REMOVAL ............................................................................................. 760 INSTALLATION......................................................................................... 760 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL............................................................. 762 SPECIAL TOOLS........................................................................................ 762 ROMOVAL ............................................................................................. 762 INSTALLATION......................................................................................... 762 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY....................................................... 764 SPECIAL TOOLS........................................................................................ 764 REMOVAL ............................................................................................. 764 INSTALLATION......................................................................................... 767 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY........................................................... 769 REMOVAL.............................................................................................. 769 INSTALLATION......................................................................................... 769 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY............................................................ 770 REMOVAL.............................................................................................. 770 INSTALLATION......................................................................................... 771 REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY...................................................... 772 SPECIAL TOOLS........................................................................................ 772 REMOVAL.............................................................................................. 772 INSTALLATION......................................................................................... 774 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY.............................................................. 775 SPECIAL TOOLS........................................................................................ 775 REMOVAL.............................................................................................. 775 INSTALLATION......................................................................................... 778 REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY ............................................................. 779 SPECIAL TOOLS........................................................................................ 779 REMOVAL.............................................................................................. 779 INSTALLATION......................................................................................... 781 DISASSEMBLY AND ASSEMBLY OF DAMPER....................................................................... 783 DISASSEMBLY OF DAMPER ASSEMBLY....................................................................... 783 DISASSEMBLY OF DAMPER COVER ASSEMBLY................................................................. 783 ASSEMBLY OF DAMPER ASSEMBLY.......................................................................... 784 ASSEMBLY OF DAMPER COVER ASSEMBLY.................................................................... 785 REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY.................................................... 786 REMOVAL.............................................................................................. 786 INSTALLATION......................................................................................... 789 DISCONNECTION OF POWER TRAIN UNIT ASSEMBLY............................................................... 790 CONNECTION OF POWER TRAIN UNIT ASSEMBLY.................................................................. 795 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY................................................................. 797 DISASSEMBLY.......................................................................................... 797 ASSEMBLY............................................................................................. 800 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY.................................................... 804 SPECIAL TOOLS........................................................................................ 804 DISASSEMBLY.......................................................................................... 804 ASSEMBLY............................................................................................. 808 DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEBLY................................................ 814 SPECIAL TOOLS........................................................................................ 814 DISASSEMBLY.......................................................................................... 814 ASSEMBLY............................................................................................. 829 DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY....................................................... 846 DISASSEMBLY ......................................................................................... 846 ASSEMBLY............................................................................................. 852 REMOVAL AND INSTALLATION OF POWER TRAIN,LUBRICATION PUMP ASSEMBLY........................................ 863 REMOVAL.............................................................................................. 863 INSTALLATION......................................................................................... 863 REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY..................................................... 864 REMOVAL ............................................................................................. 864 INSTALLATION......................................................................................... 864 REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY......................................................... 865 SPECIAL TOOLS........................................................................................ 865 REMOVAL.............................................................................................. 865 INSTALLATION......................................................................................... 865 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY......................................................... 866 SPECIAL TOOS......................................................................................... 866 DISASSEMBLY.......................................................................................... 866 ASSEMBLY............................................................................................. 872 REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY......................................................... 881 REMOVAL.............................................................................................. 881 INSTALLATION......................................................................................... 882 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY............................................................... 883 REMOVAL.............................................................................................. 883 INSTALLATION......................................................................................... 883 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY............................................................... 884 SPECIAL TOOLS........................................................................................ 884 DISASSEMBLY.......................................................................................... 884 ASSEMBLY............................................................................................. 885 SKETCH OF SPECIAL TOOL............................................................................... 888 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY....................................................... 889 SPECIAL TOOS......................................................................................... 889 REMOVAL.............................................................................................. 890 INSTALLATION......................................................................................... 899 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY....................................................... 905 SPECIAL TOOLS........................................................................................ 905 DISASSEMBLY.......................................................................................... 905 ASSEMBLY............................................................................................. 906 REMOVAL AND INSTALLATION TRACK ROLLER ASSEMBLY........................................................... 907 SPECIAL TOOLS........................................................................................ 907 REMOVAL.............................................................................................. 907 INSTALLATION......................................................................................... 908 SKETCH OF SPECIAL TOOL............................................................................... 910 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY........................................................ 911 SPECIAL TOOLS........................................................................................ 911 DISASSEMBLY.......................................................................................... 911 ASSEMBLY............................................................................................. 912 SKETCH OF SPECIAL TOOL............................................................................... 914 REMOVAL AND INSTALLATION OF BOGIE ASSEMBLY............................................................... 915 SPECIAL TOOS......................................................................................... 915 REMOVAL.............................................................................................. 915 INSTALLATION......................................................................................... 917 SKETCH OF SPECIAL TOOL............................................................................... 920 DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY............................................................... 921 SPECIAL TOOLS........................................................................................ 921 DISASSEMBLY.......................................................................................... 921 ASSEMBLY............................................................................................. 922 REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY........................................................... 923 SPECIAL TOOLS........................................................................................ 923 REMOVAL.............................................................................................. 923 INSTALLATION......................................................................................... 925 SKETCH OF SPECIAL TOOL............................................................................... 928 EXPANDING AND ASSEMBLY TRACK SHOE INSTALLATION .......................................................... 931 CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY........................................................... 931 EXPANDING TRACK SHOE ASSEMBLY ....................................................................... 932 EXPANDING TRACK SHOE ASSEMBLY........................................................................ 932 INATALLATION OF TRACK SHOE ASSEMBLY.................................................................. 933 WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ............................................................ 934 SPECIAL TOOLS........................................................................................ 934 WHOLE DISASSEMBLY.................................................................................... 935 WHOLE ASSEMBLY....................................................................................... 937 1. WHEN RECYCLING FOR LUBRICATED TRACK........................................................... 937 2. WHEN RECYCLING FOR GREASE-FILLED TRACK........................................................ 946 DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS............................................................ 951 DISASSEMBLY AND ASSEMBLY OF 1 LINK IN FIELD.............................................................. 952 SPECIAL TOOLS........................................................................................ 952 DISASSEMBLY.......................................................................................... 952 ASSEMBLY............................................................................................. 954 DISASSEMBLY AND ASSEMBLY OF MASTER LINK.................................................................. 956 SPECIAL TOOLS........................................................................................ 956 DISASSEMBLY.......................................................................................... 957 ASSEMBLY............................................................................................. 958 REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY......................................................... 961 SPECIAL TOOLS........................................................................................ 961 REMOVAL.............................................................................................. 961 INSTALLATION......................................................................................... 961 SKETCH OF SPECIAL TOOL............................................................................... 962 REMOVAL AND INSTALLATION OF EQUALIZER BAR................................................................ 963 SPECIAL TOOLS........................................................................................ 963 REMOVAL.............................................................................................. 963 INSTALLATION......................................................................................... 965 DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING........................................................ 966 SPECIAL TOOLS........................................................................................ 966 DISASSEMBLY.......................................................................................... 966 ASSEMBLY............................................................................................. 967 SKETCH OF SPECIAL TOOL............................................................................... 968 REMOVAL AND INSTALLATION OF SEGMENT TOOTH................................................................ 969 REMOVAL ............................................................................................. 969 INSTALLATION......................................................................................... 969 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY...................................................... 970 REMOVAL.............................................................................................. 970 INSTALLATION......................................................................................... 972 REMOVAL AND INSTALLATION OF WORK EQUIPMENT AND PPC PUMP ASSEMBLY......................................... 973 REMOVAL.............................................................................................. 973 INSTALLATION......................................................................................... 973 REMOVAL AND INSTALLATION OF BLADE LIFT VALVE ASSEMBLY.................................................... 974 REMOVAL ............................................................................................. 974 INSTALLATION......................................................................................... 975 DISASSEMBLY AND ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY.................................................... 976 ASSEMBLY............................................................................................. 976 DISASSEMBLY AND ASSEMBLY OF BLADE TILE AND RIPPER LOW VALVE ASSEMBLY..................................... 978 ASSEMBLY............................................................................................. 979 DISASSEMBLY AND ASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY................................................... 980 ASSEMBLY............................................................................................. 981 DISASSEMBLY AND ASSEMBLY OF PPC CHARGE VALVE ASSEMBLY.................................................... 982 ASSEMBLY............................................................................................. 982 DISASSEMBLY AND ASSEMBLY OF BLADE PPC VALVE ASSEMBLY..................................................... 983 ASSEMBLY............................................................................................. 983 DISASSEMBLY AND ASSEMBLY OF RIPPER PPC VALVE ASSEMBLY.................................................... 985 ASSEMBLY............................................................................................. 985 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY.................................................. 986 SPECIAL TOOLS........................................................................................ 986 DISASSEMBLY.......................................................................................... 986 ASSEMBLY............................................................................................. 989 DISASSEMBLY AND ASSEMBLY OF RIPPER PIN PULER CYLINDER ASSEMBLY........................................... 992 SPECIAL TOOLS........................................................................................ 992 DISASSEMBLY.......................................................................................... 992 ASSEMBLY............................................................................................. 993 REMOVAL AND INSTALLATION OF BLADE ASSEMBLY............................................................... 995 REMOVAL ............................................................................................. 995 INSTALLATION......................................................................................... 996 DISASSEMBLY AND ASSEMBLY OF BLADE ASSEMBLY............................................................... 997 DISASSEMBLY ......................................................................................... 997 ASSEMBLY............................................................................................. 999 DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY........................................................1001 DISASSEMBLY..........................................................................................1001 ASSEMBLY.............................................................................................1002 REMOVAL AND INSTALLATION OF ROPS GUARD...................................................................1004 REMOVAL..............................................................................................1004 INSTALLATION.........................................................................................1004 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY......................................................1005 REMOVAL..............................................................................................1005 INSTALLATION.........................................................................................1006 REMOVAL AND INSTALLATION OF FLOOR FRAME..................................................................1009 SPECIAL TOOLS........................................................................................1009 REMOVAL..............................................................................................1009 INSTALLATION.........................................................................................1012 REMOVAL AND INSTALLATION OF DASHBOARD ASSEMBLY...........................................................1014 SPECIAL TOOLS........................................................................................1014 REMOVAL..............................................................................................1014 INSTALLATION.........................................................................................1015 REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY.......................................................1016 REMOVAL..............................................................................................1016 INSTALLATION.........................................................................................1016 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY................................................1017 REMOVAL .............................................................................................1017 INSTALLATION.........................................................................................1019 90 OTHERS....................................................................................................1021 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM....................................................................1022 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM....................................................................1023 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(TILTDOZER)......................................................1025 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(TILTDOZER)......................................................1027 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(DUAL TILTDOZER).................................................1029 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(DUAL TILTDOZER).................................................1031 ELECTRICAL CIRCUIT DIAGRAM(1/5)..........................................................................1033 ELECTRICAL CIRCUIT DIAGRAM(2/5)..........................................................................1035 ELECTRICAL CIRCUIT DIAGRAM(3/5)..........................................................................1037 ELECTRICAL CIRCUIT DIAGRAM(4/5)..........................................................................1039 ELECTRICAL CIRCUIT DIAGRAM(5/5)..........................................................................1041 DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER........................................................1043 ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB...................................................................1044
DESCRIPTION:
KOMATSU D375A-5 SHOP MANUAL SEBM023511 – PDF DOWNLOAD
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an
accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service
workshop For ease of understanding. the manual is divided into the following chapters; these chapters are fur-
ther divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an under-
standing of the structure. but abo serves as reference material for troubleshooting.
in addition. this section may contain hydraulic circuit diagrams. electric circuit diagrams. and maintenance
of standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs. as wed as adjustments to be made at completion at the checks and repairs.
Troubleshooting charts correlating ‘Problems‘ w.th ‘Causes‘ are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing. installing. disassembling and assembling each component. as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standard for inspection of air-assembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section main» gives hydraulic circuit diagrams and Electric circuit diagram. In addition. this section may give the specifications of attachments and options together.
S.S 22/12/24
