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Komatsu D375A-5E0 Crawler Bulldozer Shop Manual SEN00986-11 – PDF DOWNLOAD
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Komatsu D375A-5E0 Crawler Bulldozer Shop Manual
SERIAL NUMBERS : 50001 and up
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Description
Komatsu D375A-5E0 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D375A-5E0 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D375A-5E0
Serial Number: 50001 and up
Book Code: SEN00986-11
Language: English
Pages: 1618
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D375A-5E0 Crawler Bulldozer Shop Manual
How to read the shop manual:
1. Composition of shop manual:
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword:
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification:
This section explains the specifications of the machine.
10. Structure, function and maintenance standard:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting are explained in Testing and adjusting.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu D375A-5E0 Crawler Bulldozer Shop Manual
COVER............................................................................................................................... 1 00 Index and foreword............................................................................................................... 0 Index........................................................................................................................... 2 Composition of shop manual.................................................................................................. 3 Table of contents........................................................................................................... 5 Foreword and general information................................................................................................ 20 Safety notice............................................................................................................... 21 How to read the shop manual................................................................................................. 26 Explanation of terms for maintenance standard............................................................................... 28 Handling of electric equipment and hydraulic component...................................................................... 30 Handling of connectors newly used for engines............................................................................... 39 How to read electric wire code.............................................................................................. 42 Precautions when carrying out operation..................................................................................... 45 Method of disassembling and connecting push-pull type coupler............................................................... 48 Standard tightening torque table............................................................................................ 51 Conversion table............................................................................................................ 55 01 Specification.................................................................................................................... 0 Specification and technical data................................................................................................ 62 Specification drawing....................................................................................................... 63 Specifications.............................................................................................................. 64 Weight table................................................................................................................ 69 Table of fuel, coolant and lubricants....................................................................................... 71 10 Structure, function and maintenance standard..................................................................................... 0 Engine and cooling system....................................................................................................... 74 Engine mount................................................................................................................ 75 Cooling system.............................................................................................................. 77 Cooling fan pump............................................................................................................ 79 Cooling fan motor........................................................................................................... 95 Power train, Part 1............................................................................................................. 104 Power train................................................................................................................. 105 Overall drawing of power train unit......................................................................................... 107 Power train hydraulic piping drawing........................................................................................ 109 Damper, universal joint..................................................................................................... 111 Torque converter, PTO....................................................................................................... 113 Scavenging pump............................................................................................................. 120 Torque converter valve...................................................................................................... 121 Power train, Part 2............................................................................................................. 136 Transmission control........................................................................................................ 137 Transmission................................................................................................................ 143 Transmission ECMV........................................................................................................... 157 Transmission lubrication relief valve....................................................................................... 163 Power train pump + lubrication pump......................................................................................... 164 Steering, brake control..................................................................................................... 165 Transfer, bevel gear shaft, steering........................................................................................ 167 Steering ECMV............................................................................................................... 177 Steering clutch ECMV, Steering brake ECMV................................................................................... 181 Parking brake valve......................................................................................................... 188 Sudden stop prevention valve................................................................................................ 189 Final drive................................................................................................................. 190 Sprocket.................................................................................................................... 195 Undercarriage and frame......................................................................................................... 198 Track frame................................................................................................................. 199 Recoil spring............................................................................................................... 201 Idler....................................................................................................................... 203 Track roller................................................................................................................ 205 Carrier roller.............................................................................................................. 207 Track roller bogie.......................................................................................................... 208 Track shoe.................................................................................................................. 209 Main frame.................................................................................................................. 213 Suspension.................................................................................................................. 215 Hydraulic system, Part 1........................................................................................................ 220 Work equipment hydraulic piping diagram..................................................................................... 221 PPC control piping diagram.................................................................................................. 225 Work equipment control...................................................................................................... 227 Hydraulic tank.............................................................................................................. 229 Accumulator................................................................................................................. 231 PPC lock valve.............................................................................................................. 232 PPC valve................................................................................................................... 233 Hydraulic cylinder.......................................................................................................... 247 Piston valve................................................................................................................ 251 Quick drop valve............................................................................................................ 252 Pin puller switch........................................................................................................... 254 Pin puller solenoid valve................................................................................................... 255 Blade control knob (Only the machine with dual tilt)........................................................................ 257 Pitch, dual tilt solenoid valve............................................................................................. 258 Work equipment pump......................................................................................................... 261 Hydraulic system, Part 2........................................................................................................ 264 Control valve............................................................................................................... 265 Self pressure reducing valve................................................................................................ 297 Work equipment.................................................................................................................. 306 Cylinder stay............................................................................................................... 307 Blade....................................................................................................................... 309 Cutting edge, end bit....................................................................................................... 313 Ripper...................................................................................................................... 315 Cab and its attachments......................................................................................................... 318 Cab mount................................................................................................................... 319 Cab......................................................................................................................... 320 Air conditioner............................................................................................................. 322 Electrical system............................................................................................................... 324 Engine control system....................................................................................................... 325 CRI engine control system................................................................................................... 335 Monitor system.............................................................................................................. 337 Machine monitor............................................................................................................. 339 Mode selection system....................................................................................................... 353 Electrical equipment........................................................................................................ 357 Palm command control system................................................................................................. 359 Sensors..................................................................................................................... 361 Vehicle health monitoring system (VHMS)..................................................................................... 365 ORBCOMM terminal system..................................................................................................... 371 20 Standard value table............................................................................................................. 0 Standard service value table.................................................................................................... 376 Standard value table for engine............................................................................................. 377 Standard value table for machine............................................................................................ 378 30 Testing and adjusting............................................................................................................ 0 Testing and adjusting, Part 1................................................................................................... 388 Tools for testing, adjusting, and troubleshooting........................................................................... 390 Testing engine speed........................................................................................................ 393 Testing intake air pressure (boost pressure)................................................................................ 396 Testing exhaust temperature................................................................................................. 398 Testing exhaust gas color................................................................................................... 400 Adjusting valve clearance................................................................................................... 402 Testing compression pressure................................................................................................ 404 Testing blow-by pressure.................................................................................................... 407 Testing engine oil pressure................................................................................................. 408 Testing EGR valve and bypass valve drive oil pressure....................................................................... 409 Handling of fuel system devices............................................................................................. 411 Releasing residual pressure from fuel system................................................................................ 411 Testing fuel pressure....................................................................................................... 412 Handling of reduced cylinder mode operation................................................................................. 413 Handling of no injection cranking operation................................................................................. 413 Testing leakage from pressure limiter and return rate from injector......................................................... 414 Bleeding air from fuel circuit.............................................................................................. 417 Testing fuel circuit for leakage............................................................................................ 419 Handling controller voltage circuit......................................................................................... 420 Replacing and adjusting alternator and air conditioner compressor belt...................................................... 420 Testing fan motor speed..................................................................................................... 421 Testing fan circuit oil pressure............................................................................................ 423 Bleeding air from fan pump.................................................................................................. 424 Adjusting fuel control dial and decelerator pedal........................................................................... 425 Testing and adjusting, Part 2................................................................................................... 428 Testing power train oil pressure............................................................................................ 430 Adjusting transmission speed sensor......................................................................................... 440 Simple procedure for testing brake performance.............................................................................. 441 Adjusting brake pedal and parking brake lever............................................................................... 443 Adjusting position of pccs lever console.................................................................................... 446 Emergency escape method when there is failure in power train................................................................ 447 Inspecting wear of sprocket................................................................................................. 449 Testing and adjusting track shoe tension.................................................................................... 450 Testing work equipment oil pressure......................................................................................... 451 Testing control circuit main pressure....................................................................................... 454 Testing PPC valve output pressure........................................................................................... 455 Adjusting play of PPC valve................................................................................................. 457 Testing output pressure of ripper pin-puller solenoid valve................................................................. 458 Checking location of cause of hydraulic drift of blade and ripper........................................................... 459 Testing leakage inside work equipment cylinder.............................................................................. 460 Releasing remaining pressure in work equipment cylinders.................................................................... 461 Bleeding air from work equipment cylinders.................................................................................. 461 Adjusting ripper lever position............................................................................................. 462 Adjusting work equipment lock lever......................................................................................... 463 Testing and adjusting operator’s cab........................................................................................ 464 Adjusting blade............................................................................................................. 468 Testing and adjusting, Part 3................................................................................................... 472 Special functions of monitor panel (EMMS)................................................................................... 473 Testing and adjusting, Part 4................................................................................................... 524 Adjustment method when controller has been replaced......................................................................... 525 Preparation work for troubleshooting for electrical equipment system........................................................ 527 Inspection procedure of diode............................................................................................... 530 Handling of optional devices................................................................................................ 531 Request for opening ORBCOMM terminal........................................................................................ 532 Initialization procedures for VHMS controller............................................................................... 534 Using method of KOMTRAX functions of ORBCOMM terminal....................................................................... 556 Precautions for replacing VHMS controller................................................................................... 559 Pm Clinic service........................................................................................................... 565 40 Troubleshooting.................................................................................................................. 0 Failure code table and fuse locations........................................................................................... 580 Failure codes table......................................................................................................... 581 Fuse locations.............................................................................................................. 591 General information on troubleshooting.......................................................................................... 596 Points to remember when troubleshooting..................................................................................... 597 Sequence of events in troubleshooting....................................................................................... 598 Check before troubleshooting................................................................................................ 599 Classification and procedures for troubleshooting........................................................................... 600 Information in troubleshooting table........................................................................................ 603 Connection table for connector pin numbers.................................................................................. 605 T- branch box and T- branch adapter table................................................................................... 641 Troubleshooting by failure code, Part 1......................................................................................... 646 Failure code [1380MW] Lockup clutch slip.................................................................................... 648 Failure code [1500L0] Transmission clutch dual engagement................................................................... 649 Failure code [15E0MW] Transmission clutch slip.............................................................................. 650 Failure code [15SAL1] When forward clutch oil pressure command current is OFF, fill signal is ON............................ 651 Failure code [15SALH] When forward clutch oil pressure command current is ON, fill signal is OFF............................ 653 Failure code [15SBL1] When reverse clutch oil pressure command current is OFF, fill signal is ON............................ 655 Failure code [15SBLH] When reverse clutch oil pressure command current is ON, fill signal is OFF............................ 657 Failure code [15SEL1] When 1st clutch oil pressure command current is OFF, fill signal is ON................................ 659 Failure code [15SELH] When 1st clutch oil pressure command current is ON, fill signal is OFF................................ 661 Failure code [15SFL1] When 2nd clutch oil pressure command current is OFF, fill signal is ON................................ 663 Failure code [15SFLH] When 2nd clutch oil pressure command current is ON, fill signal is OFF................................ 665 Failure code [15SGL1] When 3rd clutch oil pressure command current is OFF, fill signal is ON................................ 667 Failure code [15SGLH] When 3rd clutch oil pressure command current is ON, fill signal is OFF................................ 669 Failure code [1800MW] Power train clutch slip............................................................................... 671 Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON..................... 673 Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF..................... 675 Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON...................... 677 Failure code [2202LH] When left steering clutch oil pressure command current is ON, fill signal is OFF...................... 679 Failure code [2300NR] Brake thermal load abnormality........................................................................ 681 Failure code [2301L1] When right steering brake oil pressure command current is OFF, fill signal is ON...................... 683 Failure code [2301LH] When right steering brake oil pressure command current is ON, fill signal is OFF...................... 685 Failure code [2301NR] Right steering brake thermal load abnormality......................................................... 687 Failure code [2302L1] When left steering brake oil pressure command current is OFF, fill signal is ON....................... 689 Failure code [2302LH] When left steering brake oil pressure command current is ON, fill signal is OFF....................... 691 Failure code [2302NR] Left steering brake thermal load abnormality.......................................................... 693 Failure code [6001ZK] Failure code for design............................................................................... 693 Failure code [A000NS] Engine overheat....................................................................................... 694 Failure code [AA10NX] Air cleaner clogging.................................................................................. 695 Failure code [AB00MA] Alternator malfunction................................................................................ 696 Failure code [B@BAZG] Engine oil pressure low............................................................................... 697 Failure code [B@BAZK] Engine oil level reduction............................................................................ 698 Failure code [B@BCNS] Engine coolant overheat............................................................................... 699 Failure code [B@BCZK] Radiator coolant level reduction...................................................................... 700 Failure code [B@BEBF] Water in engine fuel.................................................................................. 701 Failure code [B@BFZK] Fuel level reduction.................................................................................. 702 Failure code [B@CENS] Power train oil overheat.............................................................................. 703 Failure code [B@CHZG] HSS charge oil pressure reduction..................................................................... 704 Failure code [B@CHZK] Power train oil level reduction....................................................................... 704 Failure code [B@GAZK] Battery electrolyte level reduction................................................................... 705 Failure code [B@HANS] Hydraulic oil overheat................................................................................ 705 Failure code [B@HAZK] Hydraulic oil level reduction......................................................................... 706 Troubleshooting by failure code, Part 2......................................................................................... 708 Failure code [CA111] Engine controller internal abnormality................................................................. 711 Failure code [CA115] Engine Ne/Bkup speed sensor abnormality................................................................ 713 Failure code [CA122] Charge pressure sensor abnormally high level........................................................... 715 Failure code [CA123] Charge pressure sensor abnormally low level............................................................ 717 Failure code [CA131] Throttle sensor abnormally high level.................................................................. 719 Failure code [CA132] Throttle sensor abnormally low level................................................................... 721 Failure code [CA135] Engine oil pressure sensor abnormally high level....................................................... 723 Failure code [CA141] Engine oil pressure sensor abnormally low level........................................................ 725 Failure code [CA144] Coolant temperature sensor abnormally high level....................................................... 727 Failure code [CA145] Coolant temperature sensor abnormally low level........................................................ 729 Failure code [CA153] Charge temperature sensor abnormally high level........................................................ 731 Failure code [CA154] Charge temperature sensor abnormally low level......................................................... 733 Failure code [CA187] Sensor power supply 2 abnormally low level............................................................. 734 Failure code [CA212] Engine oil temperature sensor abnormally high level.................................................... 735 Failure code [CA213] Engine oil temperature sensor abnormally low level..................................................... 737 Failure code [CA221] Ambient temperature sensor abnormally high level....................................................... 739 Failure code [CA222] Ambient temperature sensor abnormally low level........................................................ 741 Failure code [CA227] Sensor power supply 2 abnormally high level............................................................ 743 Failure code [CA234] Engine overspeed....................................................................................... 745 Failure code [CA238] Ne speed sensor power supply abnormality............................................................... 747 Failure code [CA263] Fuel temperature sensor abnormally high level.......................................................... 749 Failure code [CA265] Fuel temperature sensor abnormally low level........................................................... 751 Failure code [CA271] PCV1 short circuit..................................................................................... 753 Failure code [CA272] PCV1 disconnection..................................................................................... 755 Failure code [CA273] PCV2 short circuit..................................................................................... 757 Failure code [CA274] PCV2 disconnection..................................................................................... 759 Failure code [CA322] Injector #1 system disconnection or short circuit...................................................... 761 Failure code [CA323] Injector #5 system disconnection or short circuit...................................................... 763 Failure code [CA324] Injector #3 system disconnection or short circuit...................................................... 765 Failure code [CA325] Injector #6 system disconnection or short circuit...................................................... 767 Failure code [CA331] Injector #2 system disconnection or short circuit...................................................... 769 Failure code [CA332] Injector #4 system disconnection or short circuit...................................................... 771 Failure code [CA342] Engine controller data mismatch........................................................................ 773 Failure code [CA351] Injector drive circuit abnormality..................................................................... 775 Failure code [CA352] Sensor power supply 1 abnormally low level............................................................. 777 Failure code [CA386] Sensor power supply 1 abnormally high level............................................................ 779 Failure code [CA441] Power supply voltage abnormally low level.............................................................. 781 Failure code [CA442] Power supply voltage abnormally high level............................................................. 781 Failure code [CA449] Common rail pressure abnormally high pressure 2........................................................ 782 Failure code [CA451] Common rail pressure sensor abnormally high level...................................................... 783 Failure code [CA452] Common rail pressure sensor abnormally low level....................................................... 785 Failure code [CA553] Common rail pressure abnormally high pressure 1........................................................ 786 Failure code [CA554] Common rail pressure sensor in-range abnormality....................................................... 787 Failure code [CA559] Supply pump low pressure 1............................................................................. 788 Failure code [CA689] Engine Ne speed sensor abnormality..................................................................... 793 Failure code [CA731] Engine Bkup speed sensor phase abnormality............................................................. 795 Failure code [CA757] Engine controller all data loss........................................................................ 796 Failure code [CA778] Engine Bkup speed sensor abnormality................................................................... 797 Troubleshooting by failure code, Part 3......................................................................................... 800 Failure code [CA1228] EGR valve servo abnormality 1......................................................................... 802 Failure code [CA1625] EGR valve servo abnormality 2......................................................................... 803 Failure code [CA1633] CAN communication error (Engine controller)........................................................... 805 Failure code [CA2185] Throttle sensor power supply abnormally high level.................................................... 807 Failure code [CA2186] Throttle sensor power supply abnormally low level..................................................... 809 Failure code [CA2249] Supply pump low pressure 2............................................................................ 810 Failure code [CA2271] EGR valve lift sensor abnormally high level........................................................... 811 Failure code [CA2272] EGR valve lift sensor abnormally low level............................................................ 813 Failure code [CA2351] EGR valve solenoid drive short circuit................................................................ 815 Failure code [CA2352] EGR valve solenoid drive disconnection................................................................ 817 Failure code [D110KA] Battery relay hold line disconnection................................................................. 819 Failure code [D110KB] Battery relay hold line short circuit................................................................. 821 Failure code [D130KA] Neutral safety relay disconnection.................................................................... 823 Failure code [D130KB] Neutral safety relay short circuit.................................................................... 825 Failure code [D161KA] Backup alarm relay disconnection...................................................................... 827 Failure code [D161KB] Backup alarm relay short circuit...................................................................... 829 Failure code [D182KZ] Preheater relay disconnection or short circuit........................................................ 831 Failure code [D190KA] Engine controller ACC signal cut relay disconnection.................................................. 833 Failure code [D190KB] Engine controller ACC signal cut relay short circuit.................................................. 835 Failure code [D5ZRKA] Snap shot switch disconnection........................................................................ 837 Failure code [D5ZRKB] Snap shot switch short circuit........................................................................ 838 Failure code [DAFRKR] Machine monitor CAN communication error............................................................... 839 Failure code [daFRKR] Machine monitor CAN communication error............................................................... 841 Failure code [dAFRKR] Machine monitor CAN communication error............................................................... 843 Failure code [DAQ0KT] Transmission controller internal abnormality.......................................................... 845 Failure code [DAQ1KK] Transmission controller main power supply voltage reduction........................................... 847 Failure code [DAQ2KK] Transmission controller load power supply voltage reduction........................................... 849 Failure code [DAQ5KK] Transmission controller sensor 5V power supply (1) voltage reduction.................................. 851 Failure code [DAQ6KK] Transmission controller sensor 24V power supply voltage reduction..................................... 853 Failure code [DAQ7KK] Transmission controller sensor 5V power supply (2) voltage reduction.................................. 855 Failure code [DAQ9KQ] Transmission controller model selection signal disagreement........................................... 857 Failure code [DAQRKR] Transmission controller CAN communication error....................................................... 859 Failure code [DAQSKR] Transmission controller S-NET communication error..................................................... 861 Troubleshooting by failure code, Part 4......................................................................................... 864 Failure code [DB2RKR] Engine controller CAN communication error............................................................. 867 Failure code [dB2RKR] Engine controller CAN communication error............................................................. 869 Failure code [DB30KT] Steering controller internal abnormality.............................................................. 871 Failure code [DB31KK] Steering controller main power supply voltage reduction............................................... 873 Failure code [DB32KK] Steering controller load power supply voltage reduction............................................... 875 Failure code [DB35KK] Steering controller sensor 5V power supply (1) voltage reduction...................................... 877 Failure code [DB36KK] Steering controller sensor 24V power supply voltage reduction......................................... 879 Failure code [DB37KK] Steering controller sensor 5V power supply (2) voltage reduction...................................... 881 Failure code [DB39KQ] Steering controller model selection signal disagreement............................................... 883 Failure code [dB3RKR] Steering controller CAN communication error........................................................... 885 Failure code [DB3SKR] Steering controller S-NET communication error......................................................... 887 Failure code [DBB0KK] (or VHMS LED display "n901") VHMS supply voltage abnormality.......................................... 889 Failure code [DBB0KQ] (or VHMS LED display "nF11") VHMS connector connection abnormality.................................... 891 Failure code [DBB3KK] (or VHMS LED display "n905") VHMS controller battery direct power supply voltage reduction............ 893 Failure code [DBB5KP] (or VHMS LED display "n904") Sensor power supply (5V) system abnormality.............................. 895 Failure code [DBB6KP] (or VHMS LED display "n902") Sensor power supply (24V) system disconnection or short circuit.......... 897 Failure code [DBB7KP] (or VHMS LED display "n903") Sensor power supply (12V) system disconnection or short circuit.......... 899 Failure code [DBBQKR] (or VHMS LED display "n802") CAN communication error (VHMS controller)................................ 901 Failure code [dbBRKR] VHMS controller CAN communication error............................................................... 905 Failure code [DD12KA] Shift-up switch disconnection......................................................................... 907 Failure code [DD12KB] Shift-up switch short circuit......................................................................... 909 Failure code [DD13KA] Shift-down switch disconnection....................................................................... 911 Failure code [DD13KB] Shift-down switch short circuit....................................................................... 913 Failure code [DD14KA] Parking brake lever switch disconnection.............................................................. 915 Failure code [DD14KB] Parking brake lever switch short circuit.............................................................. 917 Failure code [DDB9L4] Reverse switch disagreement........................................................................... 919 Failure code [DDK3L4] Forward switch signal disagreement.................................................................... 921 Troubleshooting by failure code, Part 5......................................................................................... 924 Failure code [DDK5KA] Shift switch disconnection............................................................................ 927 Failure code [DDK5KB] Shift switch short circuit............................................................................ 929 Failure code [DDN2LD] Blade tilt right oil pressure switch is held down for long time....................................... 931 Failure code [DDN3LD] Blade tilt left oil pressure switch is held down for long time........................................ 933 Failure code [DDN7KA] Blade pitch switch disconnection...................................................................... 935 Failure code [DDN7KB] Blade pitch switch short circuit...................................................................... 937 Failure code [DDN9KA] Blade tilt switch disconnection....................................................................... 939 Failure code [DDN9KB] Blade tilt switch short circuit....................................................................... 941 Failure code [DDNALD] Blade lift raise oil pressure switch is held down for long time....................................... 943 Failure code [DDNBLD] Ripper lift raise oil pressure switch is held down for long time...................................... 945 Failure code [DDNCLD] Ripper lift lower oil pressure switch is held down for long time...................................... 947 Failure code [DDNDLD] Ripper tilt in oil pressure switch is held down for long time......................................... 949 Failure code [DDNELD] Ripper tilt back oil pressure switch is held down for long time....................................... 951 Failure code [DDNFLD] Blade lift lower oil pressure switch is held down for long time....................................... 953 Failure code [DDQ2KA] Parking brake lever switch disconnection.............................................................. 955 Failure code [DDQ2KB] Parking brake lever switch short circuit.............................................................. 957 Failure code [DDQ2L4] Parking brake lever switch ON/OFF signal disagreement................................................. 959 Failure code [dDQ2L4] Parking brake lever switch ON/OFF signal disagreement................................................. 960 Failure code [DDT5KA] Neutral switch disconnection.......................................................................... 961 Failure code [DDT5KB] Neutral switch short circuit.......................................................................... 963 Failure code [DDT5KQ] Lever specification selection signal disagreement..................................................... 965 Failure code [DGE5KX] (or VHMS LED display "n40") Ambient temperature sensor system disconnection or short circuit.......... 967 Failure code [DGS1KX] Hydraulic oil temperature sensor signal out of range.................................................. 969 Failure code [DGT1KA] Power train oil temperature sensor disconnection...................................................... 971 Failure code [DGT1KX] Power train oil temperature sensor input signal out of range.......................................... 973 Failure code [DGT5KA] (or VHMS LED display "n322") Front exhaust temperature sensor system short circuit.................... 975 Failure code [DGT5KB] (or VHMS LED display "n321") Front exhaust temperature sensor system disconnection.................... 977 Failure code [DGT6KA] (or VHMS LED display "n312") Rear exhaust temperature sensor system short circuit..................... 979 Failure code [DGT6KB] (or VHMS LED display "n311") Rear exhaust temperature sensor system disconnection..................... 981 Failure code [DH22KA] Work equipment pump oil pressure sensor 1 disconnection............................................... 983 Failure code [DH22KB] Work equipment pump oil pressure sensor 1 short circuit............................................... 985 Failure code [DH23KA] Work equipment pump oil pressure sensor 2 disconnection............................................... 987 Failure code [DH23KB] Work equipment pump oil pressure sensor 2 short circuit............................................... 989 Failure code [DHE5KB] (or VHMS LED display "n332") Engine blow-by pressure sensor system disconnection...................... 991 Failure code [DHE5KY] (or VHMS LED display "n331") Engine blow-by pressure sensor system short circuit...................... 993 Failure code [DHT3KX] (or VHMS LED display "n614") Transmission oil pressure sensor input signal out of range............... 995 Failure code [DK10KA] Fuel control dial disconnection....................................................................... 997 Failure code [DK10KB] Fuel control dial short circuit....................................................................... 999 Troubleshooting by failure code, Part 6.........................................................................................1002 Failure code [DK30KA] Steering potentiometer 1 disconnection................................................................1004 Failure code [DK30KB] Steering potentiometer 1 short circuit................................................................1006 Failure code [DK30KX] Steering potentiometer 1 input signal out of range....................................................1008 Failure code [DK30KZ] Steering potentiometer 1 disconnection or short circuit...............................................1009 Failure code [DK30L8] Steering potentiometer 1 analog signal disagreement...................................................1010 Failure code [DK31KA] Steering potentiometer 2 disconnection................................................................1011 Failure code [DK31KB] Steering potentiometer 2 short circuit................................................................1013 Failure code [DK40KA] Brake potentiometer disconnection.....................................................................1015 Failure code [DK40KB] Brake potentiometer short circuit.....................................................................1017 Failure code [DK55KX] Direction potentiometer input signal out of range.....................................................1019 Failure code [DK55KZ] Direction potentiometer disconnection or short circuit................................................1020 Failure code [DK55L8] Direction potentiometer analog signal disagreement....................................................1021 Failure code [DK56KA] Direction potentiometer 1 disconnection...............................................................1022 Failure code [DK56KB] Direction potentiometer 1 short circuit...............................................................1024 Failure code [DK57KA] Direction potentiometer 2 disconnection...............................................................1026 Failure code [DK57KB] Direction potentiometer 2 short circuit...............................................................1028 Failure code [DK60KA] Acceleration sensor disconnection.....................................................................1030 Failure code [DK60KB] Acceleration sensor short circuit.....................................................................1032 Failure code [DKH1KA] Pitch angle sensor disconnection......................................................................1034 Failure code [DKH1KB] Pitch angle sensor short circuit......................................................................1036 Failure code [DKH1KX] Pitch angle sensor input signal out of range..........................................................1037 Failure code [DLF1KA] Torque converter output speed sensor disconnection....................................................1038 Failure code [DLT3KA] Transmission output speed sensor disconnection 1......................................................1039 Failure code [dLT3KA] Transmission output speed sensor disconnection 2......................................................1040 Failure code [DLT3KB] Transmission output speed sensor short circuit........................................................1041 Failure code [DV00KB] Alarm buzzer short circuit............................................................................1042 Failure code [DW59KA] Blade dual selector solenoid disconnection............................................................1043 Failure code [DW59KB] Blade dual selector solenoid short circuit............................................................1044 Failure code [DW59KY] Blade dual selector solenoid hot short................................................................1045 Failure code [DW5AKA] Blade pitch selector solenoid disconnection...........................................................1046 Failure code [DW5AKB] Blade pitch selector solenoid short circuit...........................................................1047 Failure code [DW5AKY] Blade pitch selector solenoid hot short...............................................................1048 Failure code [DW7BKA] Fan reverse solenoid disconnection....................................................................1049 Failure code [DW7BKB] Fan reverse solenoid short circuit....................................................................1050 Failure code [DW7BKY] Fan reverse solenoid hot short........................................................................1051 Failure code [DWN3KA] Sudden stop prevention solenoid disconnection.........................................................1052 Failure code [DWN3KB] Sudden stop prevention solenoid short circuit.........................................................1054 Failure code [DWN3KY] Sudden stop prevention solenoid hot short.............................................................1056 Failure code [DWN5KA] Fan pulley solenoid 1 disconnection...................................................................1058 Failure code [DWN5KB] Fan pulley solenoid 1 short circuit...................................................................1060 Failure code [DWN5KY] Fan pulley solenoid 1 hot short.......................................................................1062 Failure code [DWNCKA] Fan pulley solenoid 2 disconnection...................................................................1064 Failure code [DWNCKB] Fan pulley solenoid 2 short circuit...................................................................1066 Failure code [DWNCKY] Fan pulley solenoid 2 hot short.......................................................................1068 Troubleshooting by failure code, Part 7.........................................................................................1071 Failure code [DXH1KA] Lockup solenoid disconnection.........................................................................1073 Failure code [DXH1KB] Lockup solenoid short circuit.........................................................................1075 Failure code [DXH1KY] Lockup solenoid hot short.............................................................................1077 Failure code [DXH4KA] 1st clutch ECMV disconnection.........................................................................1079 Failure code [DXH4KB] 1st clutch ECMV short circuit.........................................................................1081 Failure code [DXH4KY] 1st clutch ECMV hot short.............................................................................1083 Failure code [DXH5KA] 2nd clutch ECMV disconnection.........................................................................1085 Failure code [DXH5KB] 2nd clutch ECMV short circuit.........................................................................1087 Failure code [DXH5KY] 2nd clutch ECMV hot short.............................................................................1089 Failure code [DXH6KA] 3rd clutch ECMV disconnection.........................................................................1091 Failure code [DXH6KB] 3rd clutch ECMV short circuit.........................................................................1093 Failure code [DXH6KY] 3rd clutch ECMV hot short.............................................................................1095 Failure code [DXH7KA] Reverse clutch ECMV disconnection.....................................................................1097 Failure code [DXH7KB] Reverse clutch ECMV short circuit.....................................................................1099 Failure code [DXH7KY] Reverse clutch ECMV hot short.........................................................................1101 Failure code [DXH8KA] Forward clutch ECMV hot short.........................................................................1103 Failure code [DXH8KB] Forward clutch ECMV short circuit.....................................................................1105 Failure code [DXH8KY] Forward clutch ECMV hot short.........................................................................1107 Failure code [DXH9KA] Right steering clutch ECMV disconnection..............................................................1109 Failure code [DXH9KB] Right steering clutch ECMV short circuit..............................................................1111 Failure code [DXH9KY] Right steering clutch ECMV hot short..................................................................1113 Failure code [DXHAKA] Left steering clutch ECMV disconnection...............................................................1115 Failure code [DXHAKB] Left steering clutch ECMV short circuit...............................................................1117 Failure code [DXHAKY] Left steering clutch ECMV hot short...................................................................1119 Failure code [DXHBKA] Right brake ECMV disconnection........................................................................1121 Failure code [DXHBKB] Right brake ECMV short circuit........................................................................1123 Failure code [DXHBKY] Right brake ECMV hot short............................................................................1125 Failure code [DXHCKA] Left brake ECMV disconnection.........................................................................1127 Failure code [DXHCKB] Left brake ECMV short circuit.........................................................................1129 Failure code [DXHCKY] Left brake ECMV hot short.............................................................................1131 Failure code [F@BBZL] (or VHMS LED display "n338") Engine blow-by pressure abnormally high level............................1133 Failure code [F@BYNR] (or VHMS LED display "n362") Front exhaust temperature abnormally high level (2)......................1134 Failure code [F@BYNS] (or VHMS LED display "n361") Front exhaust temperature abnormally high level (1)......................1136 Failure code [F@BZNR] (or VHMS LED display "n372") Rear exhaust temperature abnormally high level (2).......................1138 Failure code [F@BZNS] (or VHMS LED display "n371") Rear exhaust temperature abnormally high level (1).......................1140 Troubleshooting of electrical system (E-mode)...................................................................................1143 Information in troubleshooting table........................................................................................1145 E-1 The engine does not start...............................................................................................1146 E-2 Preheat does not operate (Manual preheating function)...................................................................1151 E-3 The ripper pin puller cylinder does not operate.........................................................................1154 E-4 When the starting switch is ON, none of the machine monitor come on.....................................................1156 E-5 When the starting switch is turned ON, the machine monitor completely remains lighted and does not go out...............1158 E-6 When the starting switch is ON, the basic check item flashes............................................................1160 E-7 While the engine is operating, any caution item flashes.................................................................1162 E-8 An emergency caution item flashes while the engine is running...........................................................1165 E-9 While the preheater is operating, the preheating pilot lamp does not come on............................................1170 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)....1172 E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on..................1172 E-12 The engine coolant temperature gauge does not indicate normally........................................................1173 E-13 Indication of the power train (torque converter) temperature gauge is abnormal.........................................1174 E-14 The hydraulic oil temperature gauge does not indicate normally.........................................................1176 E-15 Indication of the fuel gauge is abnormal...............................................................................1177 E-16 Indications of gear speed and engine speed are abnormal................................................................1178 E-17 Indication of the shift mode service meter is abnormal.................................................................1178 E-18 The switch module cannot be operated...................................................................................1179 E-19 The warning lamp does not flash or does not go out.....................................................................1180 E-20 The alarm buzzer does not sound or does not stop.......................................................................1181 E-21 Auto shift down is not possible or is not released.....................................................................1182 E-22 The alarm buzzer cannot be cancelled...................................................................................1183 E-23 The operator mode cannot be operated...................................................................................1184 E-24 The service mode cannot be operated....................................................................................1186 E-25 The back-up alarm does not sound.......................................................................................1188 E-26 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on..........................1190 E-27 Air conditioner does not operate.......................................................................................1196 E-28 Orbcomm terminal does not operate normally (Data are not transmitted)..................................................1200 E-29 Fan does not reverse...................................................................................................1202 E-30 Gear cannot be shifted.................................................................................................1204 E-31 Electric priming pump does not operate or does not stop automatically..................................................1206 Troubleshooting of hydraulic and mechanical system (H-mode).....................................................................1209 Information in troubleshooting table........................................................................................1211 H-1 No force (no drawbar pull)..............................................................................................1212 H-2 No travel (at 2nd or 3rd speed).........................................................................................1214 H-3 No travel at all gear speeds............................................................................................1216 H-4 Machine travels only in one direction forward or in reverse.............................................................1218 H-5 Large time lag at gear speed shifting or forward-reverse shifting.......................................................1219 H-6 Steering is not possible................................................................................................1220 H-7 Steering is possible only on one side...................................................................................1221 H-8 Steering overrun occurs.................................................................................................1222 H-9 Brake does not work.....................................................................................................1223 H-10 Torque converter is not lock-up........................................................................................1224 H-11 Power train oil overheats..............................................................................................1225 H-12 All work equipment operates slowly.....................................................................................1226 H-13 All work equipment does not operate....................................................................................1227 H-14 Blade lift speed is slow or lacks power................................................................................1228 H-15 Blade tilt speed is slow or lacks power................................................................................1228 H-16 Ripper lift speed is slow or lacks power...............................................................................1229 H-17 Ripper tilt speed is slow or lacks power...............................................................................1229 H-18 Excessive hydraulic drift of blade lift................................................................................1230 H-19 Excessive hydraulic drift of blade tilt................................................................................1231 H-20 Excessive hydraulic drift of ripper lift...............................................................................1232 H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine).............................................1233 H-22 Blade pitch does not work (dual tilt attachment machine)...............................................................1234 H-23 Abnormal sound comes out from around work equipment pump...............................................................1235 H-24 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats)...............................1236 Troubleshooting of engine (S-mode)..............................................................................................1239 Method of using troubleshooting chart.......................................................................................1241 S-1 Engine does not start easily............................................................................................1244 S-2 Engine does not start...................................................................................................1246 S-3 Engine does not pick up smoothly (follow-up is poor)....................................................................1250 S-4 Engine stops during operation...........................................................................................1251 S-5 Engine does not rotate smoothly (hunting)...............................................................................1252 S-6 Engine lacks output (or lacks power)....................................................................................1253 S-7 Exhaust smoke is black (Incomplete combustion)..........................................................................1255 S-8 Oil is consumed much (or exhaust gas color is blue).....................................................................1257 S-9 Engine oil becomes contaminated quickly.................................................................................1258 S-10 Fuel consumption is excessive..........................................................................................1259 S-11 Coolant contains oil (blows back or reduces)...........................................................................1260 S-12 Oil pressure lamp lights up (drop in oil pressure).....................................................................1261 S-13 Oil level rises (Water, fuel in oil)...................................................................................1262 S-14 Coolant temperature rises too high (Overheating).......................................................................1264 S-15 Abnormal noise is made.................................................................................................1265 S-16 Vibration is excessive.................................................................................................1266 S-17 Air cannot be bled from fuel circuit..................................................................................1268 50 Disassembly and assembly......................................................................................................... 0 General information on disassembly and assembly.................................................................................1271 How to read this manual.....................................................................................................1272 Coating materials list......................................................................................................1274 Special tool list...........................................................................................................1277 Sketchs of special tools....................................................................................................1287 Engine and cooling system.......................................................................................................1297 Removal and installation of engine assembly.................................................................................1298 Removal and installation of cooling assembly (radiator, aftercooler and hydraulic oil cooler)...............................1303 Removal and installation of radiator........................................................................................1306 Removal and installation of hydraulic oil cooler............................................................................1308 Removal and installation of aftercooler.....................................................................................1309 Removal and installation of radiator guard assembly.........................................................................1310 Removal and installation of fuel tank assembly..............................................................................1314 Removal and installation of engine hood assembly............................................................................1315 Removal and installation of fan drive assembly..............................................................................1317 Removal and installation of fan motor assembly..............................................................................1319 Engine..........................................................................................................................1323 Removal and installation of fuel supply pump assembly.......................................................................1324 Removal and installation of cylinder head assembly..........................................................................1328 Removal and installation of fuel injector assembly..........................................................................1344 Removal and installation of engine front seal...............................................................................1349 Removal and installation of engine rear seal................................................................................1351 Power train, Part 1.............................................................................................................1357 Removal and installation of damper assembly.................................................................................1358 Disassembly and assembly of damper..........................................................................................1362 Removal and installation of power train unit assembly.......................................................................1365 Disconnection and connection of power train unit assembly...................................................................1369 Disassembly and assembly of PTO assembly....................................................................................1375 Disassembly and assembly of torque converter assembly.......................................................................1381 Disassembly and assembly of torqflow transmission assembly..................................................................1390 Power train, Part 2.............................................................................................................1415 Disassembly and assembly of steering case assembly..........................................................................1416 Removal and installation of power train, lubrication pump assembly..........................................................1431 Removal and installation of scavenging pump assembly........................................................................1432 Removal and installation of final drive assembly............................................................................1433 Disassembly and assembly of final drive assembly............................................................................1434 Undercarriage and frame, Part 1.................................................................................................1447 Removal and installation of track frame assembly............................................................................1448 Removal and installation of idler assembly..................................................................................1453 Disassembly and assembly of idler assembly..................................................................................1454 Removal and installation of recoil spring assembly..........................................................................1457 Disassembly and assembly of recoil spring assembly..........................................................................1462 Removal and installation track roller assembly..............................................................................1464 Disassembly and assembly of track roller assembly...........................................................................1467 Removal and installation of carrier roller assembly.........................................................................1469 Disassembly and assembly of carrier roller assembly.........................................................................1470 Removal and installation of bogie assembly..................................................................................1473 Disassembly and assembly of bogie assembly..................................................................................1478 Removal and installation of 1st bogie assembly..............................................................................1480 Undercarriage and frame, Part 2.................................................................................................1487 Expansion and installation of track shoe assembly...........................................................................1488 Whole disassembly and assembly of track shoe................................................................................1491 Dimensions table of fitting jig of link press...............................................................................1508 Disassembly and assembly of 1 link in the field.............................................................................1509 Disassembly and assembly of master link.....................................................................................1513 Removal and installation of pivot shaft assembly............................................................................1518 Removal and installation of equalizer bar...................................................................................1519 Disassembly and assembly of equalizer bar bushing...........................................................................1522 Removal and installation of segment tooth...................................................................................1524 Hydraulic system................................................................................................................1527 Removal and installation of hydraulic tank and control valve assembly.......................................................1528 Removal and installation of work equipment pump assembly....................................................................1531 Removal and installation of fan pump assembly...............................................................................1533 Removal and installation of control valve assembly..........................................................................1536 Assembly of control valve assembly..........................................................................................1538 Disassembly and assembly of PPC charge valve assembly.......................................................................1544 Disassembly and assembly of blade PPC valve assembly........................................................................1545 Disassembly and assembly of ripper PPC valve assembly.......................................................................1547 Disassembly and assembly of hydraulic cylinder assembly.....................................................................1548 Disassembly and assembly of ripper pin puller cylinder assembly.............................................................1553 Work equipment..................................................................................................................1557 Removal and installation of blade assembly..................................................................................1558 Disassembly and assembly of blade assembly..................................................................................1560 Disassembly and assembly of giant ripper assembly...........................................................................1564 Cab and its attachments.........................................................................................................1569 Removal and installation of ROPS guard......................................................................................1570 Removal and installation of operator’s cab assembly.........................................................................1571 Removal and installation of floor frame assembly............................................................................1575 Electrical system...............................................................................................................1581 Removal and installation of transmission and steering controller assembly...................................................1582 Removal and installation of engine controller assembly......................................................................1583 Removal and installation of VHMS controller assembly........................................................................1585 Removal and installation of air conditioner unit assembly...................................................................1586 Removal and installation of monitor panel assembly..........................................................................1589 90 Diagrams and drawings............................................................................................................ 0 Hydraulic diagrams and drawings.................................................................................................1591 Hydraulic circuit diagram (1/2).............................................................................................1593 Hydraulic circuit diagram (2/2).............................................................................................1594 Power train hydraulic circuit diagram.......................................................................................1595 Electrical diagrams and drawings................................................................................................1598 Electrical circuit diagram (1/13)...........................................................................................1600 Electrical circuit diagram (2/13)...........................................................................................1601 Electrical circuit diagram (3/13)...........................................................................................1602 Electrical circuit diagram (4/13)...........................................................................................1603 Electrical circuit diagram (5/13)...........................................................................................1604 Electrical circuit diagram (6/13)...........................................................................................1605 Electrical circuit diagram (7/13)...........................................................................................1606 Electrical circuit diagram (8/13)...........................................................................................1607 Electrical circuit diagram (9/13)...........................................................................................1608 Electrical circuit diagram (10/13)..........................................................................................1609 Electrical circuit diagram (11/13)..........................................................................................1610 Electrical circuit diagram (12/13)..........................................................................................1611 Electrical circuit diagram (13/13)..........................................................................................1612 Electrical circuit diagram for inside cab...................................................................................1613 Air conditioner unit electrical circuit diagram.............................................................................1614 Connectors table and arrangement drawing....................................................................................1616
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