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Komatsu D375A-5 (VHMS Specification) Crawler Bulldozer Shop Manual SEBM036103 – PDF DOWNLOAD
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Komatsu D375A-5 (VHMS Specification) Crawler Bulldozer Shop Manual
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D375A-5 (VHMS Specification) 18052 and up
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Description
Komatsu D375A-5 (VHMS Specification) Crawler Bulldozer Shop Manual SEBM036103
FILE DETAILS:
Komatsu D375A-5 (VHMS Specification) Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D375A-5 (VHMS Specification)
Serial Number: 18052 and up
Book Code: SEBM036103
Language: English
Pages: 1034
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D375A-5 (VHMS Specification) Crawler Bulldozer Shop Manual
FOREWORD:
GENERAL:
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 further 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 understanding of the structure, but also serves as reference material for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “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 standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu D375A-5 (VHMS Specification) Crawler Bulldozer Shop Manual
COVER..................................................................................................................................... 1 CONTENTS.................................................................................................................................. 2 01 GENERAL................................................................................................................................ 29 SPECIFICATION DRAWING................................................................................................................. 30 SPECIFICATIONS........................................................................................................................ 31 WEIGHT TABLE.......................................................................................................................... 36 TABLE OF FUEL, COOLANT AND LUBRICANT.................................................................................................. 38 10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD........................................................................................... 39 POWER TRAIN........................................................................................................................... 40 OVERALL DRAWING OF POWER TRAIN UNIT................................................................................................... 42 POWER TRAIN HYDRAULIC PIPING DRAWING.................................................................................................. 44 DAMPER, UNIVERSAL JOINT............................................................................................................... 45 TORQUE CONVERTER, PTO................................................................................................................. 47 TORQUE CONVERTER VALVE................................................................................................................ 54 SCAVENGING PUMP....................................................................................................................... 65 TRANSMISSION CONTROL.................................................................................................................. 66 TRANSMISSION.......................................................................................................................... 68 TRANSMISSION ECMV..................................................................................................................... 78 TRANSMISSION LUBRICATION RELIEF VALVE................................................................................................. 84 POWER TRAIN PUMP + LUBRICATION PUMP................................................................................................... 85 STEERING, BRAKE CONTROL............................................................................................................... 86 TRANSFER, BEVEL GEAR SHAFT, STEERING.................................................................................................. 88 STEERING ECMV......................................................................................................................... 95 STEERING CLUTCH, STEERING BRAKE ECMV.................................................................................................. 99 PARKING BRAKE VALVE................................................................................................................... 106 SUDDEN STOPS PREVENTION VALVE......................................................................................................... 107 FINAL DRIVE........................................................................................................................... 108 TRACK FRAME........................................................................................................................... 113 RECOIL SPRING......................................................................................................................... 115 IDLER................................................................................................................................. 117 TRACK ROLLER.......................................................................................................................... 119 CARRIER ROLLER........................................................................................................................ 120 TRACK ROLLER BOGIE.................................................................................................................... 121 TRACK SHOE............................................................................................................................ 122 MAIN FRAME............................................................................................................................ 124 SUSPENSION............................................................................................................................ 126 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM............................................................................................... 129 PPC CONTROL PIPING DIAGRAM............................................................................................................ 133 WORK EQUIPMENT CONTROL................................................................................................................ 134 HYDRAULIC TANK........................................................................................................................ 136 PPC CHARGE VALVE...................................................................................................................... 137 ACCUMULATOR........................................................................................................................... 140 PPC LOCK VALVE........................................................................................................................ 141 PPC VALVE............................................................................................................................. 142 WORK EQUIPMENT CYLINDER............................................................................................................... 152 PISTON VALVE.......................................................................................................................... 155 QUICK DROP VALVE...................................................................................................................... 156 PIN PULLER SWITCH..................................................................................................................... 158 PIN PULLER SOLENOID VALVE............................................................................................................. 159 BLADE CONTROL KNOB.................................................................................................................... 161 PITCH, DUAL TILT SOLENOID VALVE....................................................................................................... 162 WORK EQUIPMENT + PPC CHARGE PUMP...................................................................................................... 164 MAIN CONTROL VALVE.................................................................................................................... 166 CYLINDER STAY......................................................................................................................... 195 BLADE................................................................................................................................. 196 RIPPER EQUIPMENT...................................................................................................................... 201 CAB MOUNT............................................................................................................................. 203 CAB................................................................................................................................... 204 AIR CONDITIONER....................................................................................................................... 206 ENGINE CONTROL........................................................................................................................ 207 ENGINE CONTROL SYSTEM................................................................................................................. 208 DECELERATOR POTENTIOMETER............................................................................................................. 209 HPI ENGINE CONTROL SYSTEM............................................................................................................. 210 MONITOR SYSTEM........................................................................................................................ 212 MONITOR PANEL......................................................................................................................... 214 MODE SELECTION SYSTEM................................................................................................................. 221 ELECTRICAL DEVICE..................................................................................................................... 226 STEERING ELECTRONIC CONTROL........................................................................................................... 228 VHMS CONTROLLER....................................................................................................................... 230 COMMUNICATION (ORB:ORBCOMM) CONTROLLER/ANTENNA........................................................................................ 237 20 TESTING AND ADJUSTING.................................................................................................................. 238 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS......................................................................................... 239 STANDARD VALUE TABLE FOR MACHINE RELATED PARTS........................................................................................ 240 TESTING AND ADJUSTING................................................................................................................. 248 TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING.................................................................................. 249 MEASURING ENGINE SPEED............................................................................................................ 251 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).................................................................................... 254 MEASURING EXHAUST TEMPERATURE..................................................................................................... 255 MEASURING EXHAUST COLOR........................................................................................................... 257 TROUBLESHOOTING FOR INJECTOR...................................................................................................... 258 ADJUSTING VALVE CLEARANCE......................................................................................................... 259 ADJUSTING INJECTOR SET LOAD....................................................................................................... 260 MEASURING COMPRESSION PRESSURE.................................................................................................... 262 MEASURING BLOW-BY PRESSURE........................................................................................................ 264 MEASURING ENGINE OIL PRESSURE..................................................................................................... 265 HANDLING EQUIPMENT IN FUEL SYSTEM................................................................................................. 266 MEASURING FUEL CIRCUIT PRESSURE................................................................................................... 267 VISUAL INSPECTION OF RETURN FUEL.................................................................................................. 269 ARRANGEMENT OF CONTROL DEVICES FOR HPI............................................................................................ 270 BLEEDING AIR FROM FUEL CIRCUIT.................................................................................................... 272 ADJUSTING ENGINE SPEED SENSOR..................................................................................................... 274 REPLACING AND ADJUSTING FAN BELT.................................................................................................. 275 TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER COMPRESSOR BELT TENSION......................................................... 276 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL................................................................................. 277 MEASURING POWER TRAIN OIL PRESSURE................................................................................................ 279 ADJUSTING TRANSMISSION SPEED SENSOR............................................................................................... 289 SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE.................................................................................... 289 ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER .................................................................................... 290 ADJUSTING POSITION OF PCCS LEVER CONSOLE.......................................................................................... 293 EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER TRAIN...................................................................... 294 ADJUSTING IDLER CLEARANCE......................................................................................................... 296 CHECKING WEAR OF SPROCKET......................................................................................................... 296 TESTING AND ADJUSTING TRACK SHOE TENSION.......................................................................................... 297 TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE................................................................................. 298 TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE............................................................................... 303 MEASURING PPC VALVE OUTPUT PRESSURE............................................................................................... 305 ADJUSTING PLAY OF PPC VALVE....................................................................................................... 307 MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE..................................................................... 308 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER................................................................. 309 MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER.................................................................................. 310 RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS.......................................................................... 311 BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS........................................................................................ 311 ADJUSTING RIPPER LEVER POSITION................................................................................................... 312 ADJUSTING WORK EQUIPMENT LOCK LEVER............................................................................................... 313 ADJUSTING BLADE................................................................................................................... 314 ADJUSTMENT OF PCCS LEVER POTENTIOMETERS........................................................................................... 316 CHECKING THE ADJUSTMENT OF PCCS LEVER............................................................................................. 318 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)......................................................................................... 321 ADJUSTMENT METHOD OF REPLACED CONTROLLER.......................................................................................... 372 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRICAL EQUIPMENT SYSTEM.............................................................. 374 HANDLING OF OPTIONAL DEVICES...................................................................................................... 377 INITIALIZATION PROCEDURES FOR VHMS CONTROLLER..................................................................................... 378 PROCEDURES FOR EXECUTING QUICK PM................................................................................................. 383 PRECAUTIONS FOR REPLACING VHMS CONTROLLER......................................................................................... 392 PM CLINIC SERVICE................................................................................................................. 393 UNDERCARRIAGE TROUBLESHOOTING REPORT (NORMAL)..................................................................................... 400 UNDERCARRIAGE TROUBLESHOOTING REPORT (IMPACT)..................................................................................... 401 TROUBLESHOOTING....................................................................................................................... 402 POINTS TO REMEMBER WHEN TROUBLESHOOTING........................................................................................... 403 SEQUENCE OF EVENTS IN TROUBLESHOOTING............................................................................................. 404 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.................................................................................. 405 CHECKS BEFORE TROUBLESHOOTING..................................................................................................... 413 CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING............................................................................... 414 CONNECTOR ALLOCATION DRAWING ..................................................................................................... 417 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................................ 428 T-BRANCH BOX AND T-BRANCH TABLE................................................................................................... 451 TROUBLESHOOTING WHEN ERROR CODE DISPLAYED (ERROR CODE)............................................................................ 453 INFORMATION CONTAINED IN TROUBLESHOOTING TABLE................................................................................ 458 ERROR CODE[1500LO](TRANSMISSION CLUTCH DOUBLE ERROR).......................................................................... 460 ERROR CODE[15SAL1](DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD CLUTCH).................................................... 461 ERROR CODE[15SALH](DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)....................................................... 462 ERROE CODE[15SBL1](DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE CLUTCH).................................................... 463 ERROR CODE[15SBLH](DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE CLUTH)........................................................ 464 ERROR CODE[15SELH](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST CLUTCH)........................................................ 465 ERROR CODE[15SELH](DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH)........................................................... 466 ERROR CODE[15SFL1](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND CLUTCH)........................................................ 467 ERROR CODE[15SFLH](DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH)........................................................... 468 ERROR CODE[15SGL1](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD CLUTCH)........................................................ 469 ERROR CODE[15SGLH](DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH)........................................................... 470 ERROR CODE[1800MW](SLIP OF POWER TRAIN CLUTCH)................................................................................ 471 ERROR CODE[2201L1](DEFECTIVE DISENGAGEMENT OF RIGHT STEERING CLUTCH).......................................................... 472 ERROR CODE[2201LH](DEFECTIVE ENGAGEMENT OF RIGHT STEERING CLUTCH)............................................................. 473 ERROR CODE[2201L1](DEFECTIVE DISENGAGEMENT OF LEFT STEERING CLUTCH)........................................................... 474 ERROR CODE[2202LH](DEFECTIVE ENGAGEMENT OF LEFT STEERING CLUTCH).............................................................. 475 ERROR CODE[2300NR](BRAKE ABNORMAL HEATING).................................................................................... 476 ERROR CODE[2301L1](DEFECTIVE DISENGAGEMENT OF RIGHT STEERING BRAKE)........................................................... 477 ERROR CODE[2301LH](DEFECTIVE ENGAGEMENT OF RIGHT STEERING BRAKE).............................................................. 478 ERROR CODE[2301NR](RIGHT STEERING BRAKE ABNORMAL HEATING)..................................................................... 479 ERROR CODE[2302L1](DEFECTIVE DISENGAGEMENT OF LEFT STERING BRAKE)............................................................. 480 ERROR CODE[2302LH](DEFECTIVE ENGAGEMENT OF LEFT STEERING BRAKE)............................................................... 481 ERROR CODE[2302NR](LEFT STEERING BRAKE ABNORMAL HEATING)...................................................................... 482 ERROR CODE[AB00MA](ALTERNATOR MALFUNCTION).................................................................................... 482 ERROR CODE[B@BAZG](ENGINE OIL PRESSURE REDUCTION)............................................................................. 483 ERROR CODE[B@BCNS](RADIATOR COOLANT OVERHEAT)................................................................................. 484 ERROR CODE[B@BCZK](RADIATOR COOLANT LEVEL REDUCTION).......................................................................... 484 ERROR CODE[B@CENS](POWER TRAIN OIL OVERHEAT).................................................................................. 485 ERROR CODE[B@HANS](HYDRAULIC OIL OVERHEAT).................................................................................... 485 ERROR CODE[C111KT](ABNORMALITY IN ENGINE CONTROLLER MEMORY)................................................................... 486 ERROR CODE[C112LK](ABNORMALITY IN TIMIMG RAIL ACTUATOR)....................................................................... 486 ERROR CODE[C113KZ](ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM)........................................................... 487 ERROR CODE[C115KZ](ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS).............................................................. 488 ERROR CODE[C116KZ](ABNORMALLY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)............................................... 490 ERROR CODE[C117KX](ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)................................................ 491 ERROR CODE[C118KX](ABNORMALLY HIGH LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM)................................................. 492 ERROR CODE[C119KX](ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM).................................................. 493 ERROR CODE[C121LC](ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS).............................................................. 493 ERROR CODE[C122KX](ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM)..................................................... 494 ERROR CODE[C123KX](ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM)...................................................... 495 ERROR CODE[C131KX](ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM)........................................................... 496 ERROR CODE[C132KX](ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM)............................................................ 497 EROOR CODE[C133KX](ABNORMALLY HIGH LEVEL IN REMOTE THROTTLR SENSOR SYSTEM).................................................... 498 ERROR CODE[C134KX](ABNORMALLY LOW LEVEL IN REMOTE THROTTLE SENSOR SYSTEM)..................................................... 499 ERROR CODE[C135KX](ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM)................................................ 500 ERROR CODE[C141KX](ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM)................................................. 501 ERROR CODE[C143ZG](LOWERING OF ENGINE OIL PRESSURE)........................................................................... 501 ERROR CODE[C144KX](ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM)......................................... 502 ERROR CODE[C145KX](ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM).......................................... 503 ERROR CODE[C151NS](RISE OF ENGINE COOANT TEMPERATURE)......................................................................... 503 ERROR CODE[C153KX](ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM)............................................. 504 ERROR CODE[C154KX](ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM).............................................. 505 ERROR CODE[C221KX](ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)............................................... 506 ERROR CODE[C222KX](ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)................................................ 507 ERROR CODE[C234N1](OVER-SPEED)................................................................................................ 507 ERROR CODE[C254KZ](ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)................................................................... 508 ERROR CODE[C259FS](ABNORMALLY IN FUEL SHUT-OFF VALVE)......................................................................... 509 ERROR CODE[C261NS](ABNORMAL RISE OF FUEL TEMPERATURE)......................................................................... 509 ERROR CODE[C263KX](ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)................................................... 510 ERROE CODE[C265KX](ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM).................................................... 511 ERROR CODE[C316KZ](ABNORMAL CURRENT OF FUEL PUMP ACTUATOR).................................................................... 512 ERROR CODE[C318LK](ABNORMALITY IN FUEL PUMP ACTUATOR)......................................................................... 513 ERROR CODE[C346KT](ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER)....................................................... 514 ERROR CODE[C384LK](ABNORMALITY IN PREHEATER CONTROL SYSTEM)................................................................... 516 ERROR CODE[C423L6](ABNORMALITY IN IN-RANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM)............................................. 518 ERROE CODE[C441KK](ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM) ........................................................... 520 ERROR CODE[C442KG](ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM)........................................................... 520 ERROR CODE[C451KX](ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM)................................................. 521 ERROR CODE[C452KX](ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM).................................................. 522 ERROR CODE[C455KZ](ABNORMAL CURRENT OF FUEL RAIL ACTUATOR).................................................................... 523 ERROR CODE[C467LK](ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)............................................................... 524 ERROR CODE[C468LK](ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)................................................................. 524 ERROR CODE[C514LK](ABNORMALITY IN FUEL RAIL ACTUATOR)......................................................................... 525 ERROR CODE[C554L6](ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM)............................................... 526 ERROR CODE[C110KA](DISCONNECTION IN BATTERY RELAY SYSTEM)..................................................................... 528 ERROR CODE[D110KB](SHORT CIRCUIT IN BATTERY RELAY SYSTEM)..................................................................... 529 ERROR CODE[D130KA](DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM).............................................................. 530 ERROR CODE[D130KB](SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM).............................................................. 532 ERROR CODE[D161KA](DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)............................................................... 534 ERROR CODE[D161KB](SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)............................................................... 536 ERROR CODE[D190KA](DISCONNECTION IN ACC SIGNAL DRIVE RELAY SYSTEM)............................................................ 538 ERROR CODE[D190KB](SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM) ........................................................... 539 ERROR CODE[D5ZRKA](DISCONNECTION IN SNAP SHOT SIGNAL)......................................................................... 540 ERROR CODE[D5ZRKB](SHORT CIRUIT IN SNAP SHOT SIGNAL).......................................................................... 541 ERROR CODE[DAFRKR](DEFECTIVE OF MONITOR PANEL CAN COMMUNICATION).............................................................. 542 ERROR CODE[DAQ0KK](ABNORMALITY IN TRANSMISSION CONTROLLER POWER SUPPLY SYSTEM)................................................ 544 ERROR CODE[DAQ0KT](ABNORMALITY IN TRANSMISSION CONTROLLER ROM)................................................................ 546 ERROR CODE[DAQ5KK](ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER SUPPLY SYSTEM)............................................ 547 ERROR CODE[DAQ6KK](ABNORMALITY IN TRANSMISSION CONTROLLER 24 V POWER SUPPLY SYSTEM)........................................... 549 ERROR CODE[DAQ9KQ](ABNORMALITY IN SELECTION OF TRANSMISSION CONTROLLER SPECIFICATION)......................................... 550 ERROR CODE[DAQRKR](DEFECTIVE OF TRANSMISSION CONTROLER CAN COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM)).......... 551 ERROR CODE[DAQSKR](DEFECTIVE OF TRANSMISSION CONTROLLER S-NET COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM))....... 553 ERROR CODE[DB30KK](ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY SYSTEM).................................................... 555 ERROR CODE[DB30KT](ABNORMALITY IN STEERING CONTROLLER ROM).................................................................... 557 ERROR CODE[DB35KK](ABNORMALITY IN STEERING CONTROLLER 5 V POWER SUPPLY SYSTEM)................................................ 558 ERROR CODE[DB36KK](ABNORMALITY IN STEERING CONTROLLER 24 V POWER SUPPLY SYSTEM)............................................... 560 ERROR CODE[DB39KQ](ABNORMALITY IN SELECTION OF STEERING CONTROLLER SPECIFICATION)............................................. 561 ERROR CODE[DB3RKR](DEFECTIVE OF STEERING CONTROLLER CAN COMMUNICATION(ABNORMALITY IN OBJECTIVE COMPONENT SYSTEM))............. 562 ERROR CODE[DB3SKR](ABNORMALITY IN NETWORK SYSTEM(STEERING))................................................................... 564 ERROR CODE[DBBRKR](ABNORMALITY IN J1939 COMMUNICATION SYSTEM)................................................................. 565 ERROR CODE[DD12KA](DISCONNECTION IN SHIFT-UP SWITCH SYSTEMS).................................................................. 566 ERROR CODE[DD12KB](SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS).................................................................. 568 ERROR CODE[DD13KA](DISCONNECTION IN SHIFT-DOWN SWITCH SYSTEMS)................................................................ 570 ERROR CODE[DD13KB](SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS)................................................................ 572 ERROR CODE[DD14KA](DISCONNECTION IN PARKING BRAKE LEVER SWITCH SYSTEMS)....................................................... 574 ERROR CODE[DD14KB](SHORT CIRCUIT IN PARKING BRAKE LEVEL SWITCH SYSTEMS)....................................................... 576 ERROR CODE[DD59KA](DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID SYSTEM)...................................................... 578 ERROR CODE[DD59KB](SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLECOID SYSTEM)...................................................... 579 ERROR CODE[DD5AKA](DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID SYSTEM)..................................................... 580 ERROR CODE[DD5AKB](SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID SYSTEM)..................................................... 581 ERROR CODE[DDN2LD](SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM).............................................. 582 ERROR CODE[DDN3LD](SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM)............................................... 583 ERROR CODE[DDN7KA](DISCONNECTION IN BLADE PITCH SWITCH SYSTEMS)............................................................... 584 ERROR CODE[DDN7KB](SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS)............................................................... 586 ERROR CODE[DDN9KA](DISCONNECTION IN BLADE TILT SWITCH SYSTEMS)................................................................ 588 ERROR CODE[DDN9KB](SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS)................................................................ 590 ERROR CODE[DDN1LD](BLADE LIFT RAISE FULL OIL PRESSURE SWITCH:REFER TO TABLE (LD))............................................. 592 ERROR CODE[DDNALD](ABNORMALITY IN BLADE LIFT RAISE FULL OIL PRESSURE SWITCH).................................................. 593 ERROR CODE[DDNBLD](SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE SWITCH SYSTEM)............................................. 594 ERROR CODE[DDNCLD](SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE SWITCH SYSTEM)............................................. 595 ERROR CODE[DDNDLD](SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH SYSTEM)................................................ 596 ERROR CODE[DDNELD](ABNORMALITY IN RIPPER TILT BACK OIL PRESSURE SWITCH)....................................................... 597 ERROR CODE[DDNFLD](ABNORMALITY IN BLADE LIFT LOWER FULL OIL PRESSURE SWITCH).................................................. 598 ERROR CODE[DDQ2KA](DISCONNECTION IN PARKING BRAKE LEVER SWITCH SYSTEMS)....................................................... 599 ERROR CODE[DDQ2KB](SHORT CIRCUIT IN PARKING BRAKE LEVER SWITCH SYSTEMS)....................................................... 601 ERROR CODE[dDQ2L4](DISAGREEMENT OF PARKING BRAKE LEVEL SWITCH SYSTEM SIGNALS)................................................. 603 ERROR CODE[DDQ2L4](DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)................................................. 604 ERROR CODE[DGS1KX](DEFECTIVE OF HYDRAULIC OIL TEMPERATURE SENSOR)............................................................. 605 ERROR CODE[DH22KA](DISCONNECTION IN FRONT PUMP OIL PRESSURE SENSOR SYSTEM).................................................... 606 ERROR CODE[DH22KB](SHORT CIRCUIT IN FRONT PUMP OIL PRESSURE SENSOR SYSTEM).................................................... 607 ERROR CODE[DH23KA](DISCONNECTION IN CENTER PUMP OIL PRESSURE SENSOR SYSTEM)................................................... 608 ERROR CODE[DH23KB](SHORT CIRCUIT IN CENTER PUMP OIL PRESSURE SENSOR SYSTEM)................................................... 609 ERROR CODE[DK10KA](DISCONNECTION IN FUEL CONTROL DIAL SYSTEM )................................................................ 610 ERROR CODE[DK10KB](SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM)................................................................. 611 ERROR CODE[DK30KA](DISCONNECTION IN STEERING POTENTIOMETER 1 SYSTEM).......................................................... 612 ERROR CODE[DK30KB](SHORT CIRCUIT IN STEERING POTENTIOMETER 1 SYSTEM).......................................................... 614 ERROR CODE[DK30KX](ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(1))..................................................... 615 ERROR CODE[DK30KZ](ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(2)) .................................................... 615 ERROR CODE[DK30L8](DEVIATION OF STEERING POTENTIOMETER SYSTEM SIGNALS)........................................................ 616 ERROR CODE[DK31KA](DISCONNECTION IN STEERING POTENTIOMETER 2 SYSTEM).......................................................... 617 ERROR CODE[DK31KB](SHORT CIRCUIT IN STEERING POTENTIOMETER 2 SYSTEM).......................................................... 618 ERROR CODE[DK40KA](DISCONNECTION IN BRAKE POTENTIOMETER SYSTEM)............................................................... 619 ERROR CODE[DK40KB](SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM)............................................................... 621 ERROR CODE[DK55KX](FORWARD-REVERSE POTENTIOMETER INPUT SIGNAL IS OUT OF NORMAL RANGE)......................................... 622 ERROR CODE[DK55KZ](DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER)........................................... 622 ERROR CODE[DK55L8](DISCREPANCY OF FORWARD-REVERSE POTENTIOMETER).............................................................. 623 ERROR CODE[DK56KA](DISCONNECTION IN FORWARD-REVERSE POTENTIOMETER 1).......................................................... 624 ERROR CODE[DK56KB](SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 1).......................................................... 625 ERROR CODE[DK57KA](DISCONNECTION IN FORWARD-REVERSE POTENTIOMETER 2 SYSTEM)................................................... 626 ERROR CODE[DK57KB](SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 2 SYSTEM)................................................... 628 ERROR CODE[DK60KA](DISCONNECTION IN ACCELERATION SENSOR SYSTEM)............................................................... 629 ERROR CODE[DK60KB](SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM)............................................................... 630 ERROR CODE[DKH1KA](DISCONNECTION IN PITCH ANGLE SENSOR SYSTEM)................................................................ 631 ERROR CODE[DKH1KB](SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)................................................................ 633 ERROR CODE[DKH1KX](DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM) ............................................. 634 ERROR CODE[dLE1KA](DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM) .............................................................. 635 ERROR CODE[DLE1KA](DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)............................................................... 636 ERROR CODE[DLF1KA](DISCONNECTION IN TORQUE CONVERTER OUTPUT SPFED SENSOR)..................................................... 637 ERROR CODE[dLT3KA](DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)......................................................... 638 ERROR CODE[DLT3KA](DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)......................................................... 640 ERROR CODE[DV00KB](SHORT CIRCUIT IN CAUTION BUZZER)........................................................................... 642 ERROR CODE[DWN3KA](DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)................................................... 643 ERROR CODE[DWN3KB](SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)................................................... 644 ERROR CODE[DXH1KA](DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)................................................. 645 ERROR CODE[DXH1KB](SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)................................................. 646 ERROR CODE[DXH4KA](DISCONNECTION IN TRANSMISSION 1ST CLUTCH ECMV (E-POCV) SYSTEM)............................................. 647 ERROR CODE[DXH4KB](SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV(E-POCV) SYSTEM).............................................. 648 ERROR CODE[DXH5KA](DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV(E-POCV) SYSTEM).............................................. 649 ERROR CODE[DXH5KB](SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV(E-POCV) SYSTEM).............................................. 650 ERROR CODE[DXH6KA](DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV(E-POCV) SYSTEM).............................................. 651 ERROR CODE[DXH6KB](SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV(E-POCV) SYSTEM).............................................. 652 ERROR CODE[DXH7KA](DISCONNECTION IN TRANSMISSION REVERSE CLUTCH ECMV(E-POCV) SYSTEM).......................................... 653 ERROR CODE[DXH7KB](SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV(E-POCV) SYSTEM).......................................... 654 ERROR CODE[DXH8KA](DISCONNECTION IN TRANSMISSION FORWARD CLUTCH ECMV(E-POCV) SYSTEM).......................................... 655 ERROR CODE[DXH8KB](SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH ECMV(E-POCV) SYSTEM).......................................... 656 ERROR CODE[DXH9KA](DISCONNECTION IN RIGHT STEERING CLUTCH ECMV(E-POCV) SYSTEM)................................................ 657 ERROR CODE[DXH9KB](SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV(E-POCV) SYSTEM)................................................ 658 ERROR CODE[DXHAKA](DISCONNECTION IN LEFT STEERING CLUTCH ECMV(E-POCV) SYSTEM)................................................. 659 ERROR CODE[DXHAKB](SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV(F-POCV) SYSTEM)................................................. 660 ERROR CODE[DXHBKA](DISCONNECTION IN RIGHT STEERING BRAKE ECMV(E-POCV) SYSTEM)................................................. 661 ERROR CODE[DXHBKB](SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV(E-POCV) SYSTEM)................................................. 662 ERROR CODE[DXHCKA](DISCONNECTION IN LEFT STEERING BRAKE ECMV(E-POCV) SYSTEM).................................................. 663 ERROR CODE[DXHCB](SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV(E-POCV) SYSTEM)................................................... 664 TROUBLESHOOTING OF ELECTRICAL SYSTEM(E-MODE)...................................................................................... 665 INFORMATION IN TROUBLESHOOTING TABLE.......................................................................................... 666 E-1 THE ENGINE DOES NOT START................................................................................................. 667 E-2 PREHEAT DOES NOT OPERATE(MANUAL PREHEATING FUNCTION)...................................................................... 669 E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE........................................................................... 671 E-4 THE MONITOR PANEL DOES NOT COME ON AT WHEN THE STARTING SWITCH IS TURNED ON............................................... 672 E-5 WHEN THE STARTING TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT............................. 673 E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES.............................................................. 674 E-7 WHEN THE ENGINE IS OPERATING, THE CAUTION ITEM FLASHES.................................................................... 675 E-8 WHEN THE ENGINE IS OPERATING, THE EMERGENCY ALARM ITEM FLASHES............................................................ 677 E-9 THE PREHEATING LAMP DOES NOT COME ON...................................................................................... 680 E-10 THE DISPLAY OF THE ENGINE COOLANT TEMPERATURE GAUGE IS NOT NORMAL........................................................ 681 E-11 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COME ON. (DUAL TILT-MOUNTED MACHINE) .... 682 E-12 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON.................... 682 E-13 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT NORMAL.................................................. 683 E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY........................................................... 684 E-15 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL.............................................................................. 685 E-16 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL.................................................................. 686 E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL................................................................... 686 E-18 THE SWITCH MODULE CANNOT BE OPERATED..................................................................................... 687 E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT....................................................................... 688 E-20 THE ALARM BUZZER DOES NOT SOUND OR STOP.................................................................................. 689 E-21 THE ALARM BUZZER CANNOT BE CANCELLED..................................................................................... 690 E-22 THE OPERATOR MODE CANNOT BE OPERATED ................................................................................... 691 E-23 THE SERVICE MODE CANNOT BE OPERATED...................................................................................... 692 E-24 INSTRUMENT PANEL NIGHT LAMP, HEADLAMP, WORKING LAMP AND REAR LAMP DO NOT COME ON......................................... 694 E-25 AIR CONDITIONER DOES NOT OPERATE......................................................................................... 698 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)....................................................................... 701 INFORMATION IN TROUBLESHOOTING TABLE.......................................................................................... 702 H-1 NO FORCE (NO DRAWBAR PULL)................................................................................................ 703 H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)........................................................................................... 704 H-3 NO TRAVEL AT ALL GEAR SPEEDS.............................................................................................. 705 H-4 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING......................................................... 706 H-5 LARGE TIME LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING......................................................... 707 H-6 STEERING IS NOT POSSIBLE.................................................................................................. 708 H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE..................................................................................... 708 H-8 STEERING OVERRUN OCCURS................................................................................................... 709 H-9 BRAKE DOES NOT WORK....................................................................................................... 709 H-10 TORQUE CONVERTER IS NOT LOCK-UP.......................................................................................... 710 H-11 TORQUE CONVERTER OIL IS OVERHEATED....................................................................................... 710 H-12 ALL WORK EQUIPMENT OPERATES SLOWLY....................................................................................... 711 H-13 ALL WORK EQUIPMENT DOES NOT OPERATE...................................................................................... 712 H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER.......................................................... 713 H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER.......................................................... 713 H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER........................................................ 714 H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER.............................................................. 714 H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE................................................................................... 715 H-19 HYDRAULIC DRIFT OF BLADE TILT IS LARGE................................................................................... 715 H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE.................................................................................. 716 H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE.............................................................................. 716 H-22 BLADE PITCH DOES NOT OPERATE............................................................................................. 717 H-23 ABNORMAL NOISE OCCURS AROUND THE WORK EQUIPMENT PUMP..................................................................... 717 TROUBLESHOOTING OF THE ENGINE BODY (S-MODE)....................................................................................... 718 POINTS TO REMEMBER WHEN TROUBLESHOOTING....................................................................................... 719 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................ 720 S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME).................................................................. 723 S-2 ENGINE DOES NOT START..................................................................................................... 725 1) ENGINE DOES NOT TURN................................................................................................... 725 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)............................................... 726 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL IS BEING INJECTED).............................................. 728 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...................................................................... 730 S-4 ENGINE STOPS DURING OPERATIONS............................................................................................ 732 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................................. 734 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...................................................................................... 736 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................................ 738 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)................................................................... 740 S-9 OIL BECOMES CONTAMINATED QUICKLY.......................................................................................... 741 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................ 742 S-11 OIL IS IN COOLANT, OR COOLANT SPURTS BACK, OR COOLANT LEVEL GOES DOWN.................................................... 743 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................................... 744 S-13 OIL LEVEL RISES.......................................................................................................... 745 S-14 COOLANT TEMPERATURE BECOMES TOO HIGH (OVERHEATING)....................................................................... 746 S-15 ABNORMAL NOISE IS MADE................................................................................................... 747 S-16 VIBRATION IS EXCESSIVE................................................................................................... 748 30 DISASSEMBLY AND ASSEMBLY............................................................................................................... 749 HOW TO READ THIS MANUAL .............................................................................................................. 752 REMOVAL AND INSTALLATION OF ASSEMBLIES............................................................................................ 752 DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES............................................................................................ 753 PRECAUTIONS WHEN CARRYING OUT OPERATION............................................................................................... 754 SPECIAL TOOL LIST..................................................................................................................... 756 SKETCHES OF SPECIAL TOOLS............................................................................................................. 765 REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY........................................................................................ 771 REMOVAL .......................................................................................................................... 771 INSTALLATION...................................................................................................................... 771 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL......................................................................................... 772 SPECIAL TOOLS..................................................................................................................... 772 REMOVAL .......................................................................................................................... 772 INSTALLATION...................................................................................................................... 772 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL.......................................................................................... 774 SPECIAL TOOLS..................................................................................................................... 774 REMOVAL .......................................................................................................................... 774 INSTALLATION...................................................................................................................... 774 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.................................................................................... 776 SPECIAL TOOLS..................................................................................................................... 776 REMOVAL .......................................................................................................................... 776 INSTALLATION...................................................................................................................... 779 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY........................................................................................ 781 REMOVAL........................................................................................................................... 781 INSTALLATION...................................................................................................................... 781 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY......................................................................................... 782 REMOVAL........................................................................................................................... 782 INSTALLATION...................................................................................................................... 783 REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY................................................................................... 784 SPECIAL TOOLS..................................................................................................................... 784 REMOVAL........................................................................................................................... 784 INSTALLATION...................................................................................................................... 786 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY........................................................................................... 787 SPECIAL TOOLS..................................................................................................................... 787 REMOVAL........................................................................................................................... 787 INSTALLATION...................................................................................................................... 790 REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY .......................................................................................... 791 SPECIAL TOOLS..................................................................................................................... 791 REMOVAL........................................................................................................................... 791 INSTALLATION...................................................................................................................... 793 DISASSEMBLY AND ASSEMBLY OF DAMPER.................................................................................................... 795 DISASSEMBLY OF DAMPER ASSEMBLY.................................................................................................... 795 DISASSEMBLY OF DAMPER COVER ASSEMBLY.............................................................................................. 795 ASSEMBLY OF DAMPER ASSEMBLY....................................................................................................... 796 ASSEMBLY OF DAMPER COVER ASSEMBLY................................................................................................. 797 REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY................................................................................. 798 REMOVAL........................................................................................................................... 798 INATALLATION...................................................................................................................... 801 DISCONNECTION OF POWER TRAIN UNIT ASSEMBLY............................................................................................ 802 CONNECTION OF POWER TRAIN UNIT ASSEMBLY............................................................................................... 807 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY.............................................................................................. 809 DISASSEMBLY....................................................................................................................... 809 ASSEMBLY.......................................................................................................................... 812 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY................................................................................. 816 SPECIAL TOOLS..................................................................................................................... 816 DISASSEMBLY....................................................................................................................... 816 ASSEMBLY.......................................................................................................................... 820 DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY............................................................................ 826 SPECIAL TOOLS..................................................................................................................... 826 DISASSEMBLY....................................................................................................................... 826 ASSEMBLY.......................................................................................................................... 841 DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY.................................................................................... 858 DISASSEMBLY ...................................................................................................................... 858 ASSEMBLY.......................................................................................................................... 864 REMOVAL AND INSTALLATION OF POWER TRAIN, LUBRICATION PUMP ASSEMBLY.................................................................... 875 REMOVAL........................................................................................................................... 875 INSTALLATION...................................................................................................................... 875 REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY.................................................................................. 876 REMOVAL .......................................................................................................................... 876 INSTALLATION...................................................................................................................... 876 REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY...................................................................................... 877 SPECIAL TOOLS..................................................................................................................... 877 REMOVAL........................................................................................................................... 877 INSTALLATION...................................................................................................................... 877 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY...................................................................................... 878 SPECIAL TOOS...................................................................................................................... 878 DISASSEMBLY....................................................................................................................... 878 ASSEMBLY.......................................................................................................................... 884 REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY...................................................................................... 893 REMOVAL........................................................................................................................... 893 INSTALLATION...................................................................................................................... 894 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY............................................................................................ 895 REMOVAL........................................................................................................................... 895 INSTALLATION...................................................................................................................... 895 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY............................................................................................ 896 SPECIAL TOOLS..................................................................................................................... 896 DISASSEMBLY....................................................................................................................... 896 ASSEMBLY.......................................................................................................................... 897 SKETCH OF SPECIAL TOOL............................................................................................................ 900 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY.................................................................................... 901 SPECIAL TOOS...................................................................................................................... 901 REMOVAL........................................................................................................................... 901 INSTALLATION...................................................................................................................... 904 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 TOOLS........................................................................................................... 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 ....................................................................................... 930 CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY........................................................................................ 930 EXPANDING TRACK SHOE ASSEMBLY .................................................................................................... 931 EXPANDING TRACK SHOE ASSEMBLY..................................................................................................... 931 INSTALLATION OF TRACK SHOE ASSEMBLY............................................................................................... 932 WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE ......................................................................................... 933 SPECIAL TOOLS..................................................................................................................... 933 WHOLE DISASSEMBLY................................................................................................................. 934 WHOLE ASSEMBLY.................................................................................................................... 936 1. WHEN RECYCLING FOR LUBRICATED TRACK........................................................................................ 936 2. WHEN RECYCLING FOR GREASE-FILLED TRACK..................................................................................... 945 DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS......................................................................................... 950 DISASSEMBLY AND ASSEMBLY OF 1 LINK IN THE FIELD....................................................................................... 951 SPECIAL TOOLS..................................................................................................................... 951 DISASSEMBLY....................................................................................................................... 951 ASSEMBLY.......................................................................................................................... 953 DISASSEMBLY AND ASSEMBLY OF MASTER LINK............................................................................................... 955 SPECIAL TOOLS..................................................................................................................... 955 DISASSEMBLY....................................................................................................................... 956 ASSEMBLY.......................................................................................................................... 957 REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY...................................................................................... 960 SPECIAL TOOLS..................................................................................................................... 960 REMOVAL........................................................................................................................... 960 INSTALLATION...................................................................................................................... 960 SKETCH OF SPECIAL TOOL............................................................................................................ 961 REMOVAL AND INSTALLATION OF EQUALIZER BAR............................................................................................. 962 SPECIAL TOOLS..................................................................................................................... 962 REMOVAL........................................................................................................................... 962 INSTALLATION...................................................................................................................... 964 DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING..................................................................................... 965 SPECIAL TOOLS..................................................................................................................... 965 DISASSEMBLY....................................................................................................................... 965 ASSEMBLY.......................................................................................................................... 966 SKETCH OF SPECIAL TOOL............................................................................................................ 967 REMOVAL AND INSTALLATION OF SEGMENT TOOTH............................................................................................. 968 REMOVAL .......................................................................................................................... 968 INSTALLATION...................................................................................................................... 968 REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY................................................................................... 969 REMOVAL........................................................................................................................... 969 INSTALLATION...................................................................................................................... 971 REMOVAL AND INSTALLATION OF WORK EQUIPMENT AND PPC PUMP ASSEMBLY...................................................................... 972 REMOVAL........................................................................................................................... 972 INSTALLATION...................................................................................................................... 972 REMOVAL AND INSTALLATION OF BLADE LIFT VALVE ASSEMBLY................................................................................. 973 REMOVAL .......................................................................................................................... 973 INSTALLATION...................................................................................................................... 974 DISASSEMBLY AND ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY................................................................................. 975 ASSEMBLY.......................................................................................................................... 975 DISASSEMBLY AND ASSEMBLY OF BLADE TILE AND RIPPER LOW VALVE ASSEMBLY.................................................................. 977 ASSEMBLY.......................................................................................................................... 978 DISASSEMBLY AND ASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY................................................................................ 979 ASSEMBLY.......................................................................................................................... 980 DISASSEMBLY AND ASSEMBLY OF PPC CHARGE VALVE ASSEMBLY................................................................................. 981 ASSEMBLY.......................................................................................................................... 981 DISASSEMBLY AND ASSEMBLY OF BLADE PPC VALVE ASSEMBLY.................................................................................. 982 ASSEMBLY.......................................................................................................................... 982 DISASSEMBLY AND ASSEMBLY OF RIPPER PPC VALVE ASSEMBLY................................................................................. 984 ASSEMBLY.......................................................................................................................... 984 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY............................................................................... 985 SPECIAL TOOLS..................................................................................................................... 985 DISASSEMBLY....................................................................................................................... 985 ASSEMBLY.......................................................................................................................... 988 DISASSEMBLY AND ASSEMBLY OF RIPPER PIN PULLER CYLINDER ASSEMBLY....................................................................... 991 SPECIAL TOOLS..................................................................................................................... 991 DISASSEMBLY....................................................................................................................... 991 ASSEMBLY.......................................................................................................................... 992 REMOVAL AND INSTALLATION OF BLADE ASSEMBLY............................................................................................ 994 REMOVAL .......................................................................................................................... 994 INSTALLATION...................................................................................................................... 995 DISASSEMBLY AND ASSEMBLY OF BLADE ASSEMBLY............................................................................................ 996 DISASSEMBLY ...................................................................................................................... 996 ASSEMBLY.......................................................................................................................... 998 DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY.....................................................................................1000 DISASSEMBLY.......................................................................................................................1000 ASSEMBLY..........................................................................................................................1001 REMOVAL AND INSTALLATION OF ROPS GUARD................................................................................................1003 REMOVAL...........................................................................................................................1003 INSTALLATION......................................................................................................................1003 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY...................................................................................1004 REMOVAL...........................................................................................................................1004 INSTALLATION......................................................................................................................1005 REMOVAL AND INSTALLATION OF FLOOR FRAME...............................................................................................1008 SPECIAL TOOLS.....................................................................................................................1008 REMOVAL...........................................................................................................................1008 INSTALLATION......................................................................................................................1011 REMOVAL AND INSTALLATION OF DASHBOARD ASSEMBLY........................................................................................1013 SPECIAL TOOLS.....................................................................................................................1013 REMOVAL...........................................................................................................................1013 INSTALLATION......................................................................................................................1014 REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY....................................................................................1015 REMOVAL...........................................................................................................................1015 INSTALLATION......................................................................................................................1015 REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY.............................................................................1016 REMOVAL ..........................................................................................................................1016 INSTALLATION......................................................................................................................1018 90 OTHERS.................................................................................................................................1019 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.................................................................................................1020 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.................................................................................................1021 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER)..................................................................................1022 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (TILTDOZER)..................................................................................1023 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER).............................................................................1024 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER).............................................................................1025 ELECTRICAL CIRCUIT DIAGRAM (1/7)......................................................................................................1026 ELECTRICAL CIRCUIT DIAGRAM (2/7)......................................................................................................1027 ELECTRICAL CIRCUIT DIAGRAM (3/7)......................................................................................................1028 ELECTRICAL CIRCUIT DIAGRAM (4/7)......................................................................................................1029 ELECTRICAL CIRCUIT DIAGRAM (5/7)......................................................................................................1030 ELECTRICAL CIRCUIT DIAGRAM (6/7)......................................................................................................1031 ELECTRICAL CIRCUIT DIAGRAM (7/7)......................................................................................................1032 DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER.....................................................................................1033 ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB................................................................................................1034
KOMATSU D375A-5 (VHMS SPECIFICATION) CRAWLER BULLDOZER SHOP MANUAL SEBM036103 – PDF DOWNLOAD:
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