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KOMATSU D375A-5R BULLDOZER SHOP MANUAL SEN02424-12 – PDF DOWNLOAD
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Description
KOMATSU D375A-5R BULLDOZER SHOP MANUAL SEN02424-12 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D375A-5R BULLDOZER SHOP MANUAL SEN02424-12 – PDF DOWNLOAD
Language : English
Pages : 1634
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D375A-5R BULLDOZER SHOP MANUAL SEN02424-12 – PDF DOWNLOAD
COVER............................................................................................................................... 1 00 Index and foreword............................................................................................................... 0 Index........................................................................................................................... 3 Composition of shop manual.................................................................................................. 4 Table of contents........................................................................................................... 6 Foreword and general information................................................................................................ 19 Safety notice............................................................................................................... 20 How to read the shop manual................................................................................................. 25 Explanation of terms for maintenance standard............................................................................... 27 Handling of electric equipment and hydraulic component...................................................................... 29 Handling of connectors newly used for engines............................................................................... 38 How to read electric wire code.............................................................................................. 41 Precautions when carrying out operation..................................................................................... 44 Method of disassembling and connecting push-pull type coupler............................................................... 47 Standard tightening torque table............................................................................................ 50 Conversion table............................................................................................................ 54 01 Specification.................................................................................................................... 0 Specification and technical data................................................................................................ 61 Specification drawing....................................................................................................... 62 Specifications.............................................................................................................. 63 Weight table................................................................................................................ 68 Table of fuel, coolant and lubricants....................................................................................... 70 10 Structure, function and maintenance standard..................................................................................... 0 Engine and cooling system....................................................................................................... 73 Engine mount................................................................................................................ 74 Cooling system.............................................................................................................. 76 Cooling fan pump............................................................................................................ 78 Cooling fan motor........................................................................................................... 94 Power train, Part 1............................................................................................................. 103 Power train................................................................................................................. 104 Overall drawing of power train unit......................................................................................... 106 Power train hydraulic piping drawing........................................................................................ 108 Damper, universal joint..................................................................................................... 110 Torque converter, PTO....................................................................................................... 112 Scavenging pump............................................................................................................. 119 Torque converter valve...................................................................................................... 120 Power train, Part 2............................................................................................................. 133 Transmission control........................................................................................................ 134 Transmission................................................................................................................ 140 Transmission ECMV........................................................................................................... 154 Transmission lubrication relief valve....................................................................................... 160 Power train pump + lubrication pump......................................................................................... 161 Steering, brake control..................................................................................................... 162 Transfer, bevel gear shaft, steering........................................................................................ 164 Steering ECMV............................................................................................................... 174 Steering clutch ECMV, Steering brake ECMV................................................................................... 178 Parking brake valve......................................................................................................... 185 Sudden stop prevention valve................................................................................................ 186 Final drive................................................................................................................. 187 Sprocket.................................................................................................................... 192 Undercarriage and frame......................................................................................................... 195 Track frame................................................................................................................. 196 Recoil spring............................................................................................................... 200 Idler....................................................................................................................... 204 Track roller................................................................................................................ 206 Carrier roller.............................................................................................................. 208 Track roller bogie.......................................................................................................... 209 Track shoe.................................................................................................................. 212 Main frame.................................................................................................................. 214 Suspension.................................................................................................................. 217 Hydraulic system, Part 1........................................................................................................ 223 Work equipment hydraulic piping diagram..................................................................................... 224 PPC control piping diagram.................................................................................................. 228 Work equipment control...................................................................................................... 230 Hydraulic tank.............................................................................................................. 232 Accumulator................................................................................................................. 234 PPC lock valve.............................................................................................................. 235 PPC valve................................................................................................................... 236 Hydraulic cylinder.......................................................................................................... 250 Piston valve................................................................................................................ 254 Quick drop valve............................................................................................................ 255 Pin puller switch........................................................................................................... 257 Pin puller solenoid valve................................................................................................... 258 Blade control knob.......................................................................................................... 260 Pitch, dual tilt solenoid valve............................................................................................. 261 Work equipment pump......................................................................................................... 264 Hydraulic system, Part 2........................................................................................................ 267 Control valve............................................................................................................... 268 Self pressure reducing valve................................................................................................ 300 Work equipment.................................................................................................................. 309 Cylinder stay............................................................................................................... 310 Blade....................................................................................................................... 312 Cutting edge, end bit....................................................................................................... 316 Ripper...................................................................................................................... 318 Cab and its attachments......................................................................................................... 321 Cab mount................................................................................................................... 322 Cab......................................................................................................................... 323 Air conditioner............................................................................................................. 325 Electrical system............................................................................................................... 327 Engine control system....................................................................................................... 328 CRI engine control system................................................................................................... 336 Monitor system.............................................................................................................. 338 Machine monitor............................................................................................................. 340 Mode selection system....................................................................................................... 350 Electrical equipment........................................................................................................ 354 Palm command control system................................................................................................. 356 Sensors..................................................................................................................... 358 Vehicle health monitoring system (VHMS)..................................................................................... 362 ORBCOMM terminal system..................................................................................................... 368 20 Standard value table............................................................................................................. 0 Standard service value table.................................................................................................... 373 Standard value table for engine............................................................................................. 374 Standard value table for machine............................................................................................ 375 30 Testing and adjusting............................................................................................................ 0 Testing and adjusting, Part 1................................................................................................... 385 Tools for testing, adjusting, and troubleshooting........................................................................... 387 Testing engine speed........................................................................................................ 390 Testing intake air pressure (boostpressure)................................................................................. 392 Testing exhaust temperature................................................................................................. 394 Testing exhaust gas color................................................................................................... 396 Adjusting valve clearance................................................................................................... 398 Testing compression pressure................................................................................................ 400 Testing blow-by pressure.................................................................................................... 403 Testing engine oil pressure................................................................................................. 404 Handling of fuel system devices............................................................................................. 405 Releasing residual pressure fromfuel system................................................................................. 405 Testing fuel pressure....................................................................................................... 406 Handling of reduced cylindermode operation.................................................................................. 407 Handling of no injection crankingoperation.................................................................................. 407 Testing leakage from pressure limiter and return rate from injector......................................................... 408 Bleeding air from fuel circuit.............................................................................................. 411 Testing fuel circuit for leakage............................................................................................ 413 Handling controller voltage circuit......................................................................................... 414 Replacing and adjusting alternator and air conditioner compressor belt...................................................... 414 Testing fan motor speed..................................................................................................... 415 Testing fan circuit oil pressure............................................................................................ 417 Bleeding air from fan pump.................................................................................................. 418 Adjusting fuel control dial and decelerator pedal........................................................................... 419 Testing and adjusting, Part 2................................................................................................... 423 Testing power train oil pressure............................................................................................ 425 Adjusting transmission speedsensor.......................................................................................... 435 Simple procedure for testing brake performance.............................................................................. 436 Adjusting brake pedal and parking brake lever............................................................................... 438 Adjusting position of pccs lever console.................................................................................... 441 Emergency escape method when there is failure in power train................................................................ 442 Inspecting wear of sprocket................................................................................................. 444 Testing and adjusting track shoe tension.................................................................................... 445 Testing work equipment oil pressure......................................................................................... 446 Testing control circuit main pressure....................................................................................... 448 Testing PPC valve output pressure........................................................................................... 449 Adjusting play of PPC valve................................................................................................. 451 Testing output pressure of ripper pin-puller solenoid valve................................................................. 452 Checking location of cause of hydraulic drift of blade and ripper........................................................... 453 Testing leakage inside work equipment cylinder.............................................................................. 454 Releasing remaining pressure in work equipment cylinders.................................................................... 455 Bleeding air from work equipment cylinders.................................................................................. 455 Adjusting ripper lever position............................................................................................. 456 Adjusting work equipment lock lever......................................................................................... 457 Testing and adjusting operator’s cab........................................................................................ 458 Adjusting blade............................................................................................................. 462 Testing and adjusting, Part 3................................................................................................... 465 Special functions of monitor panel (EMMS)................................................................................... 466 Testing and adjusting, Part 4................................................................................................... 517 Adjustment method when controller has been replaced......................................................................... 518 Preparation work for troubleshooting for electrical equipment system........................................................ 520 Inspection procedure of diode............................................................................................... 523 Handling of optional devices................................................................................................ 524 Request for opening ORBCOMM terminal........................................................................................ 525 Initialization procedures for VHMS controller............................................................................... 527 Using method of KOMTRAX functions of ORBCOMM terminal....................................................................... 549 Precautions for replacing VHMS controller................................................................................... 552 Pm Clinic service........................................................................................................... 558 40 Troubleshooting.................................................................................................................. 0 Failure code table and fuse locations........................................................................................... 573 Failure codes table......................................................................................................... 574 Fuse locations.............................................................................................................. 584 General information on troubleshooting.......................................................................................... 589 Points to remember when troubleshooting..................................................................................... 590 Sequence of events in troubleshooting....................................................................................... 591 Check before troubleshooting................................................................................................ 592 Classification and procedures for troubleshooting........................................................................... 593 Information in troubleshooting table........................................................................................ 596 Connection table for connector pin numbers.................................................................................. 598 T-branch box and T- branch adapter table.................................................................................... 634 Troubleshooting by failure code, Part 1......................................................................................... 639 Failure code [1380MW] Lockup clutch slip.................................................................................... 641 Failure code [1500L0] Transmission clutch 2 system abnormality.............................................................. 642 Failure code [15E0MW] Transmission clutch slip.............................................................................. 643 Failure code [15SAL1] When forward clutch oil pressure command current is OFF, fill signal is ON............................ 644 Failure code [15SALH] When forward clutch oil pressure command current is ON, fill signal is OFF............................ 646 Failure code [15SBL1] When reverse clutch oil pressure command current is OFF, fill signal is ON............................ 648 Failure code [15SBLH] When reverse clutch oil pressure command current is ON, fill signal is OFF............................ 650 Failure code [15SEL1] When 1st clutch oil pressure command current is OFF, fill signal is ON................................ 652 Failure code [15SELH] When 1st clutch oil pressure command current is ON, fill signal is OFF................................ 654 Failure code [15SFL1] When 2nd clutch oil pressure command current is OFF, fill signal is ON................................ 656 Failure code [15SFLH] When 2nd clutch oil pressure command current is ON, fill signal is OFF................................ 658 Failure code [15SGL1] When 3rd clutch oil pressure command current is OFF, fill signal is ON................................ 660 Failure code [15SGLH] When 3rd clutch oil pressure command current is ON, fill signal is OFF................................ 662 Failure code [1800MW] Power train clutch slip............................................................................... 664 Failure code [2201L1] When right steering clutch oil pressure command current is OFF, fill signal is ON..................... 666 Failure code [2201LH] When right steering clutch oil pressure command current is ON, fill signal is OFF..................... 668 Failure code [2202L1] When left steering clutch oil pressure command current is OFF, fill signal is ON...................... 670 Failure code [2202LH] When left steering clutch oil pressure command current is ON, fill signal is OFF...................... 672 Failure code [2300NR] Brake thermal load abnormality........................................................................ 674 Failure code [2301L1] When right steering brake oil pressure command current is OFF, fill signal is ON...................... 676 Failure code [2301LH] When right steering brake oil pressure command current is ON, fill signal is OFF...................... 678 Failure code [2301NR] Right steering brake thermal load abnormality......................................................... 680 Failure code [2302L1] When left steering brake oil pressure command current is OFF, fill signal is ON....................... 682 Failure code [2302LH] When left steering brake oil pressure command current is ON, fill signal is OFF....................... 684 Failure code [2302NR] Left steering brake thermal load abnormality.......................................................... 686 Failure code [6001ZK] Failure code for design............................................................................... 686 Failure code [A000NS] Engine overheat....................................................................................... 687 Failure code [AA10NX] Air cleaner clogging.................................................................................. 688 Failure code [AB00MA] Alternator malfunction................................................................................ 689 Failure code [B@BAZG] Engine oil pressure reduction......................................................................... 690 Failure code [B@BAZK] Engine oil level reduction............................................................................ 691 Failure code [B@BCNS] Engine coolant overheat............................................................................... 692 Failure code [B@BCZK] Engine coolant level reduction........................................................................ 693 Failure code [B@BEBF] Water in engine fuel.................................................................................. 694 Failure code [B@BFZK] Fuel level reduction.................................................................................. 695 Failure code [B@CENS] Power train oil overheat.............................................................................. 696 Failure code [B@CHZG] HSS charge oil pressure reduction..................................................................... 697 Failure code [B@CHZK] Power train oil level reduction....................................................................... 697 Failure code [B@GAZK] Battery electrolyte level reduction................................................................... 698 Failure code [B@HANS] Hydraulic oil overheat................................................................................ 698 Failure code [B@HAZK] Hydraulic oil level reduction......................................................................... 699 Troubleshooting by failure code, Part 2......................................................................................... 701 Failure code [CA111] Engine controller internal abnormality................................................................. 704 Failure code [CA115] Engine Ne/Bkup speed sensor abnormality................................................................ 706 Failure code [CA122] Charge pressure sensor abnormally high level........................................................... 708 Failure code [CA123] Charge pressure sensor abnormally low level............................................................ 710 Failure code [CA131] Throttle sensor abnormally high level.................................................................. 712 Failure code [CA132] Throttle sensor abnormally low level................................................................... 714 Failure code [CA135] Engine oil pressure sensor abnormally high level....................................................... 716 Failure code [CA141] Engine oil pressure sensor abnormally low level........................................................ 718 Failure code [CA144] Coolant temperature sensor abnormally high level....................................................... 720 Failure code [CA145] Coolant temperature sensor abnormally low level........................................................ 722 Failure code [CA153] Charge temperature sensor abnormally high level........................................................ 724 Failure code [CA154] Charge temperature sensor abnormally low level......................................................... 726 Failure code [CA187] Sensor power supply 2 abnormally low level............................................................. 727 Failure code [CA212] Engine oil temperature sensor abnormally high level.................................................... 728 Failure code [CA213] Engine oil temperature sensor abnormally low level..................................................... 730 Failure code [CA221] Ambient pressure sensor abnormally high level.......................................................... 732 Failure code [CA222] Ambient pressure sensor abnormally low level........................................................... 734 Failure code [CA227] Sensor power supply 2 abnormally high level............................................................ 736 Failure code [CA234] Engine overspeed....................................................................................... 738 Failure code [CA238] Ne speed sensor power supply abnormality............................................................... 740 Failure code [CA263] Fuel temperature sensor abnormally high level.......................................................... 742 Failure code [CA265] Fuel temperature sensor abnormally low level........................................................... 744 Failure code [CA271] PCV1 short circuit..................................................................................... 746 Failure code [CA272] PCV1 disconnection..................................................................................... 748 Failure code [CA273] PCV2 short circuit..................................................................................... 750 Failure code [CA274] PCV2 disconnection..................................................................................... 752 Failure code [CA322] Injector #1 system disconnection or short circuit...................................................... 754 Failure code [CA323] Injector #5 system disconnection or short circuit...................................................... 756 Failure code [CA324] Injector #3 system disconnection or short circuit...................................................... 758 Failure code [CA325] Injector #6 system disconnection or short circuit...................................................... 760 Failure code [CA331] Injector #2 system disconnection or short circuit...................................................... 762 Failure code [CA332] Injector #4 system disconnection or short circuit...................................................... 764 Failure code [CA342] Engine controller data mismatch........................................................................ 766 Failure code [CA351] Injector drive circuit abnormality..................................................................... 768 Failure code [CA352] Sensor power supply 1 abnormally low level............................................................. 770 Failure code [CA386] Sensor power supply 1 abnormally high level............................................................ 772 Failure code [CA441] Power supply voltage abnormally low level.............................................................. 774 Failure code [CA442] Power supply voltage abnormally high level............................................................. 774 Failure code [CA449] Common rail pressure abnormally high pressure 2........................................................ 775 Failure code [CA451] Common rail pressure sensor abnormally highlevel....................................................... 776 Failure code [CA452] Common rail pressure sensor abnormally lowlevel........................................................ 778 Failure code [CA553] Common rail pressure abnormally high pressure 1........................................................ 779 Failure code [CA554] Common rail pressure sensor in-range abnormality....................................................... 780 Failure code [CA559] Supply pump low pressure 1............................................................................. 781 Failure code [CA689] Engine Ne speed sensor abnormality..................................................................... 786 Failure code [CA731] Engine Bkup speed sensor phase abnormality............................................................. 788 Failure code [CA757] Engine controller all data loss........................................................................ 789 Failure code [CA778] Engine Bkup speed sensor abnormality................................................................... 790 Troubleshooting by failure code, Part 3......................................................................................... 793 Failure code [CA1633] CAN communication error (Engine controller)........................................................... 796 Failure code [CA2185] Throttle sensor power supply abnormally high level.................................................... 798 Failure code [CA2186] Throttle sensor power supply abnormally low level..................................................... 800 Failure code [CA2249] Supply pump low pressure 2............................................................................ 801 Failure code [D110KA] Battery relay hold line disconnection................................................................. 802 Failure code [D110KB] Battery relay hold line short circuit................................................................. 804 Failure code [D130KA] Neutral safety relay disconnection.................................................................... 806 Failure code [D130KB] Neutral safety relay short circuit.................................................................... 808 Failure code [D161KA] Backup alarm relay disconnection...................................................................... 810 Failure code [D161KB] Backup alarm relay short circuit...................................................................... 812 Failure code [D182KZ] Preheater relay disconnection or short circuit........................................................ 814 Failure code [D190KA] Engine controller ACC signal cut relay disconnection.................................................. 816 Failure code [D190KB] Engine controller ACC signal cut relay short circuit.................................................. 818 Failure code [D5ZRKA] Snap shot switch disconnection........................................................................ 820 Failure code [D5ZRKB] Snap shot switch short circuit........................................................................ 821 Failure code [DAFRKR] Machine monitor CAN communication error............................................................... 822 Failure code [daFRKR] Machine monitor CAN communication error............................................................... 824 Failure code [dAFRKR] Machine monitor CAN communication error............................................................... 826 Failure code [DAQ0KT] Transmission controller internal abnormality.......................................................... 828 Failure code [DAQ1KK] Transmission controller main power supply voltage reduction........................................... 830 Failure code [DAQ2KK] Transmission controller load power supply voltage reduction........................................... 832 Failure code [DAQ5KK] Transmission controller sensor 5V power supply (1) voltage reduction.................................. 834 Failure code [DAQ6KK] Transmission controller sensor 24V power supply voltage reduction..................................... 836 Failure code [DAQ7KK] Transmission controller sensor 5V power supply (2) voltage reduction.................................. 838 Failure code [DAQ9KQ] Transmission controller model selection signal disagreement........................................... 840 Failure code [DAQRKR] Transmission controller CAN communication error....................................................... 842 Failure code [DAQSKR] Transmission controller S-NET communication error..................................................... 844 Troubleshooting by failure code, Part 4......................................................................................... 847 Failure code [DB2RKR] Engine controller CAN communication error............................................................. 850 Failure code [dB2RKR] Engine controller CAN communication error............................................................. 852 Failure code [DB30KT] Steering controller internal abnormality.............................................................. 854 Failure code [DB31KK] Steering controller main power supply voltage reduction............................................... 856 Failure code [DB32KK] Steering controller load power supply voltage reduction............................................... 858 Failure code [DB35KK] Steering controller sensor 5V power supply (1) voltage reduction...................................... 860 Failure code [DB36KK] Steering controller sensor 24V power supply voltage reduction......................................... 862 Failure code [DB37KK] Steering controller sensor 5V power supply (2) voltage reduction...................................... 864 Failure code [DB39KQ] Steering controller model selection signal disagreement............................................... 866 Failure code [dB3RKR] Steering controller CAN communication error........................................................... 868 Failure code [DB3SKR] Steering controller S-NET communication error......................................................... 870 Failure code [DBB0KK] (or VHMS LED display "n901") VHMS supply voltage abnormality.......................................... 872 Failure code [DBB0KQ] (or VHMS LED display "nF11") VHMS connector connection abnormality.................................... 874 Failure code [DBB3KK] (or VHMS LED display "n905") VHMS controller battery direct power supply voltage reduction............ 876 Failure code [DBB5KP] (or VHMS LED display "n904") Sensor power supply (5V) system abnormality.............................. 878 Failure code [DBB6KP] (or VHMS LED display "n902") Sensor power supply (24V) system disconnection or short circuit.......... 880 Failure code [DBB7KP] (or VHMS LED display "n903") Sensor power supply (12V) system disconnection or short circuit.......... 882 Failure code [DBBQKR] (or VHMS LED display "n802") CAN communication error (VHMS controller)................................ 884 Failure code [dbBRKR] VHMS controller CAN communication error............................................................... 888 Failure code [DD12KA] Shift-up switch disconnection......................................................................... 890 Failure code [DD12KB] Shift-up switch short circuit......................................................................... 892 Failure code [DD13KA] Shift-down switch disconnection....................................................................... 894 Failure code [DD13KB] Shift-down switch short circuit....................................................................... 896 Failure code [DD14KA] Parking brake lever switch disconnection.............................................................. 898 Failure code [DD14KB] Parking brake lever switch short circuit.............................................................. 900 Failure code [DDB9L4] Reverse switch disagreement........................................................................... 902 Failure code [DDK3L4] Forward switch signal disagreement.................................................................... 904 Troubleshooting by failure code, Part 5......................................................................................... 907 Failure code [DDK5KA] Shift switch disconnection............................................................................ 910 Failure code [DDK5KB] Shift switch short circuit............................................................................ 912 Failure code [DDN2LD] Blade tilt right oil pressure switch is held down for long time....................................... 914 Failure code [DDN3LD] Blade tilt left oil pressure switch is held down for long time........................................ 916 Failure code [DDN7KA] Blade pitch switch disconnection...................................................................... 918 Failure code [DDN7KB] Blade pitch switch short circuit...................................................................... 920 Failure code [DDN9KA] Blade tilt switch disconnection....................................................................... 922 Failure code [DDN9KB] Blade tilt switch short circuit....................................................................... 924 Failure code [DDNALD] Blade lift raise oil pressure switch is held down for long time....................................... 926 Failure code [DDNBLD] Ripper lift raise oil pressure switch is held down for long time...................................... 928 Failure code [DDNCLD] Ripper lift lower oil pressure switch is held down for long time...................................... 930 Failure code [DDNDLD] Ripper tilt in oil pressure switch is held down for long time......................................... 932 Failure code [DDNELD] Ripper tilt back oil pressure switch is held down for long time....................................... 934 Failure code [DDNFLD] Blade lift lower oil pressure switch is held down for long time....................................... 936 Failure code [DDQ2KA] Parking brake lever switch disconnection.............................................................. 938 Failure code [DDQ2KB] Parking brake lever switch short circuit.............................................................. 940 Failure code [DDQ2L4] Parking brake lever switch ON/OFF signal disagreement................................................. 942 Failure code [dDQ2L4] Parking brake lever switch ON/OFF signal disagreement................................................. 943 Failure code [DDT5KA] Neutral switch disconnection.......................................................................... 944 Failure code [DDT5KB] Neutral switch short circuit.......................................................................... 946 Failure code [DDT5KQ] Lever specification selection signal disagreement..................................................... 948 Failure code [DGE5KX] (or VHMS LED display "n40") Ambient temperature sensor system disconnection or short circuit.......... 950 Failure code [DGS1KX] Hydraulic oil temperature sensor signal out of range.................................................. 952 Failure code [DGT1KA] Power train oil temperature sensor disconnection...................................................... 954 Failure code [DGT1KX] Power train oil temperature sensor input signal out of range.......................................... 956 Failure code [DGT5KA] (or VHMS LED display "n322") Front exhaust temperature sensor system short circuit.................... 958 Failure code [DGT5KB] (or VHMS LED display "n321") Front exhaust temperature sensor system disconnection.................... 960 Failure code [DGT6KA] (or VHMS LED display "n312") Rear exhaust temperature sensor system short circuit..................... 962 Failure code [DGT6KB] (or VHMS LED display "n311") Rear exhaust temperature sensor system disconnection..................... 964 Failure code [DH22KA] Work equipment pump oil pressure sensor 1 disconnection............................................... 966 Failure code [DH22KB] Work equipment pump oil pressure sensor 1 short circuit............................................... 968 Failure code [DH23KA] Work equipment pump oil pressure sensor 2 disconnection............................................... 970 Failure code [DH23KB] Work equipment pump oil pressure sensor 2 short circuit............................................... 972 Failure code [DHE5KB] (or VHMS LED display "n332") Engine blow-by pressure sensor system disconnection...................... 974 Failure code [DHE5KY] (or VHMS LED display "n331") Engine blow-by pressure sensor system short circuit...................... 976 Failure code [DHT3KX] (or VHMS LED display "n614") Transmission oil pressure sensor input signal out of range............... 978 Failure code [DK10KA] Fuel control dial disconnection....................................................................... 980 Failure code [DK10KB] Fuel control dial short circuit....................................................................... 982 Troubleshooting by failure code, Part 6......................................................................................... 985 Failure code [DK30KA] Steering potentiometer 1 disconnection................................................................ 988 Failure code [DK30KB] Steering potentiometer 1 short circuit................................................................ 990 Failure code [DK30KX] Steering potentiometer 1 input signal out of range.................................................... 992 Failure code [DK30KZ] Steering potentiometer 1 disconnection or short circuit............................................... 993 Failure code [DK30L8] Steering potentiometer 1 analog signal disagreement................................................... 994 Failure code [DK31KA] Steering potentiometer 2 disconnection................................................................ 996 Failure code [DK31KB] Steering potentiometer 2 short circuit................................................................ 998 Failure code [DK40KA] Brake potentiometer disconnection.....................................................................1000 Failure code [DK40KB] Brake potentiometer short circuit.....................................................................1002 Failure code [DK55KX] Direction potentiometer input signal out of range.....................................................1004 Failure code [DK55KZ] Direction potentiometer disconnection or short circuit................................................1005 Failure code [DK55L8] Direction potentiometer analog signal disagreement....................................................1006 Failure code [DK56KA] Direction potentiometer 1 disconnection...............................................................1008 Failure code [DK56KB] Direction potentiometer 1 short circuit...............................................................1010 Failure code [DK57KA] Direction potentiometer 2 disconnection...............................................................1012 Failure code [DK57KB] Direction potentiometer 2 short circuit...............................................................1014 Failure code [DK60KA] Acceleration sensor disconnection.....................................................................1016 Failure code [DK60KB] Acceleration sensor short circuit.....................................................................1018 Failure code [DKH1KA] Pitch angle sensor disconnection......................................................................1020 Failure code [DKH1KB] Pitch angle sensor short circuit......................................................................1022 Failure code [DKH1KX] Pitch angle sensor input signal out of range..........................................................1023 Failure code [DLF1KA] Torque converter output speed sensor disconnection....................................................1024 Failure code [DLT3KA] Transmission output speed sensor disconnection 1......................................................1025 Failure code [dLT3KA] Transmission output speed sensor disconnection 2......................................................1026 Failure code [DLT3KB] Transmission output speed sensor short circuit1.......................................................1027 Failure code [DV00KB] Alarm buzzer short circuit............................................................................1028 Failure code [DW59KA] Blade dual selector solenoid disconnection............................................................1029 Failure code [DW59KB] Blade dual selector solenoid short circuit............................................................1030 Failure code [DW59KY] Blade dual selector solenoid hot short................................................................1031 Failure code [DW5AKA] Blade pitch selector solenoid disconnection...........................................................1032 Failure code [DW5AKB] Blade pitch selector solenoid short circuit...........................................................1033 Failure code [DW5AKY] Blade pitch selector solenoid hot short...............................................................1034 Failure code [DW7BKA] Fan reverse solenoid disconnection....................................................................1035 Failure code [DW7BKB] Fan reverse solenoid short circuit....................................................................1036 Failure code [DW7BKY] Fan reverse solenoid hot short........................................................................1037 Failure code [DWN3KA] Sudden stop prevention solenoid disconnection.........................................................1038 Failure code [DWN3KB] Sudden stop prevention solenoid short circuit.........................................................1040 Failure code [DWN3KY] Sudden stop prevention solenoid hot short.............................................................1042 Failure code [DWN5KA] Fan pulley solenoid 1 disconnection...................................................................1044 Failure code [DWN5KB] Fan pulley solenoid 1 short circuit...................................................................1046 Failure code [DWN5KY] Fan pulley solenoid 1 hot short.......................................................................1048 Failure code [DWNCKA] Fan pulley solenoid 2 disconnection...................................................................1050 Failure code [DWNCKB] Fan pulley solenoid 2 short circuit...................................................................1052 Failure code [DWNCKY] Fan pulley solenoid 2 hot short.......................................................................1054 Troubleshooting by failure code, Part 7.........................................................................................1057 Failure code [DXH1KA] Lockup solenoid disconnection.........................................................................1060 Failure code [DXH1KB] Lockup solenoid short circuit.........................................................................1062 Failure code [DXH1KY] Lockup solenoid hot short.............................................................................1064 Failure code [DXH4KA] 1st clutch ECMV disconnection.........................................................................1066 Failure code [DXH4KB] 1st clutch ECMV short circuit.........................................................................1068 Failure code [DXH4KY] 1st clutch ECMV hot short.............................................................................1070 Failure code [DXH5KA] 2nd clutch ECMV disconnection.........................................................................1072 Failure code [DXH5KB] 2nd clutch ECMV short circuit.........................................................................1074 Failure code [DXH5KY] 2nd clutch ECMV hot short.............................................................................1076 Failure code [DXH6KA] 3rd clutch ECMV disconnection.........................................................................1078 Failure code [DXH6KB] 3rd clutch ECMV short circuit.........................................................................1080 Failure code [DXH6KY] 3rd clutch ECMV hot short.............................................................................1082 Failure code [DXH7KA] Reverse clutch ECMV disconnection.....................................................................1084 Failure code [DXH7KB] Reverse clutch ECMV short circuit.....................................................................1086 Failure code [DXH7KY] Reverse clutch ECMV hot short.........................................................................1088 Failure code [DXH8KA] Forward clutch ECMV hot short.........................................................................1090 Failure code [DXH8KB] Forward clutch ECMV short circuit.....................................................................1092 Failure code [DXH8KY] Forward clutch ECMV hot short.........................................................................1094 Failure code [DXH9KA] Right steering clutch ECMV disconnection..............................................................1096 Failure code [DXH9KB] Right steering clutch ECMV short circuit..............................................................1098 Failure code [DXH9KY] Right steering clutch ECMV hot short..................................................................1100 Failure code [DXHAKA] Left steering clutch ECMV disconnection...............................................................1102 Failure code [DXHAKB] Left steering clutch ECMV short circuit...............................................................1104 Failure code [DXHAKY] Left steering clutch ECMV hot short...................................................................1106 Failure code [DXHBKA] Right brake ECMV disconnection........................................................................1108 Failure code [DXHBKB] Right brake ECMV short circuit........................................................................1110 Failure code [DXHBKY] Right brake ECMV hot short............................................................................1112 Failure code [DXHCKA] Left brake ECMV disconnection.........................................................................1114 Failure code [DXHCKB] Left brake ECMV short circuit.........................................................................1116 Failure code [DXHCKY] Left brake ECMV hot short.............................................................................1118 Failure code [F@BBZL] (or VHMS LED display "n338") Engine blow-by pressure abnormally high level............................1120 Failure code [F@BYNR] (or VHMS LED display "n362") Front exhaust temperature abnormally high level (2)......................1122 Failure code [F@BYNS] (or VHMS LED display "n361") Front exhaust temperature abnormally high level (1)......................1124 Failure code [F@BZNR] (or VHMS LED display "n372") Rear exhaust temperature abnormally high level (2).......................1126 Failure code [F@BZNS] (or VHMS LED display "n371") Rear exhaust temperature abnormally high level (1).......................1128 Troubleshooting of electrical system (E-mode)...................................................................................1131 Information in troubleshooting table........................................................................................1133 E-1 The engine does not start...............................................................................................1134 E-2 Preheat does not operate (Manual preheating function)...................................................................1139 E-3 The ripper pin puller cylinder does not operate.........................................................................1142 E-4 When the starting switch is ON, none of the machine monitor come on.....................................................1144 E-5 When the starting switch is turned ON, the machine monitor completely remains lighted and does not go out...............1146 E-6 When the starting switch is ON, the basic check item flashes............................................................1148 E-7 While the engine is operating, any caution item flashes.................................................................1150 E-8 An emergency caution item flashes while the engine is running...........................................................1153 E-9 While the preheater is operating, the preheating pilot lamp does not come on............................................1156 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)....1158 E-11 At the locking-up of the torque converter, the torque converter lock-up display lamp does not come on..................1158 E-12 The engine coolant temperature gauge does not indicate normally........................................................1159 E-13 Indication of the power train (torque converter) temperature gauge is abnormal.........................................1160 E-14 The hydraulic oil temperature gauge does not indicate normally.........................................................1162 E-15 Indication of the fuel gauge is abnormal...............................................................................1163 E-16 Indications of gear speed and engine speed are abnormal................................................................1164 E-17 Indication of the shift mode service meter is abnormal.................................................................1164 E-18 The switch module cannot be operated...................................................................................1165 E-19 The warning lamp does not flash or does not go out.....................................................................1166 E-20 The alarm buzzer does not sound or does not stop.......................................................................1167 E-21 Auto shift down is not possible or is not released.....................................................................1168 E-22 The alarm buzzer cannot be cancelled...................................................................................1169 E-23 The operator mode cannot be operated...................................................................................1170 E-24 The service mode cannot be operated....................................................................................1172 E-25 The back-up alarm does not sound.......................................................................................1174 E-26 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on..........................1176 E-27 Air conditioner does not operate.......................................................................................1182 E-28 Orbcomm terminal does not operate normally (Data are not transmitted)..................................................1186 E-29 Fan does not reverse...................................................................................................1188 E-30 Gear cannot be shifted.................................................................................................1190 E-31 Electric priming pump does not operate or does not stop automatically..................................................1192 Troubleshooting of hydraulic, mechanical system (H-mode) .......................................................................1195 Information in troubleshooting table........................................................................................1197 H-1 No force (no drawbar pull)..............................................................................................1198 H-2 No travel (at 2nd or 3rd speed).........................................................................................1200 H-3 No travel at all gear speeds............................................................................................1202 H-4 Machine travels only in one direction forward or in reverse.............................................................1204 H-5 Large time lag at gear speed shifting or forward-reverse shifting.......................................................1205 H-6 Steering is not possible................................................................................................1206 H-7 Steering is possible only on one side...................................................................................1207 H-8 Steering overrun occurs.................................................................................................1208 H-9 Brake does not work.....................................................................................................1209 H-10 Torque converter is not lock-up........................................................................................1210 H-11 Power train oil overheats..............................................................................................1211 H-12 All work equipment operates slowly.....................................................................................1212 H-13 All work equipment does not operate....................................................................................1213 H-14 Blade lift speed is slow or lacks power................................................................................1214 H-15 Blade tilt speed is slow or lacks power................................................................................1214 H-16 Ripper lift speed is slow or lacks power...............................................................................1215 H-17 Ripper tilt speed is slow or lacks power...............................................................................1215 H-18 Excessive hydraulic drift of blade lift................................................................................1216 H-19 Excessive hydraulic drift of blade tilt................................................................................1217 H-20 Excessive hydraulic drift of ripper lift...............................................................................1218 H-21 Ripper pin puller cylinder does not work (giant ripper attachment machine).............................................1219 H-22 Blade pitch does not work (dual tilt attachment machine)...............................................................1220 H-23 Abnormal sound comes out from around work equipment pump...............................................................1221 H-24 Fan speed is abnormal (Sound and/or vibration are abnormally large or engine over heats)...............................1222 Troubleshooting of engine (S-mode)..............................................................................................1225 Method of using troubleshooting chart.......................................................................................1227 S-1 Starting performance of engine is poor..................................................................................1230 S-2 Engine does not start...................................................................................................1231 S-3 Engine does not pick up smoothly........................................................................................1234 S-4 Engine stops during operation...........................................................................................1235 S-5 Engine does not rotate smoothly.........................................................................................1236 S-6 Engine lack output (or lacks power).....................................................................................1237 S-7 Exhaust gas is black (incomplete combustion)............................................................................1238 S-8 Oil consumption is excessive (or exhaust gas is blue)...................................................................1240 S-9 Oil becomes dirty quickly...............................................................................................1241 S-10 Fuel consumption is excessive..........................................................................................1242 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..................................................1243 S-12 Oil pressure drops.....................................................................................................1244 S-13 Oil level rises (Entry of coolant or fuel).............................................................................1245 S-14 Coolant temperature becomes too high (overheating).....................................................................1246 S-15 Abnormal noise is made.................................................................................................1247 S-16 Vibration is excessive.................................................................................................1248 S-17 Air cannot be bled from fuel circuit...................................................................................1250 50 Disassembly and assembly......................................................................................................... 0 General information on disassembly and assembly.................................................................................1253 How to read this manual.....................................................................................................1253 Coating materials list......................................................................................................1253 Special tool list...........................................................................................................1259 Sketchs of special tools....................................................................................................1270 Engine and cooling system (SAA6D170E-5).........................................................................................1281 Removal and installation of engine assembly.................................................................................1282 Removal and installation of radiator assembly (with aftercooler and hydraulic oil cooler)...................................1288 Removal and installation of radiator unit...................................................................................1292 Removal and installation of hydraulic oil cooler assembly...................................................................1294 Removal and installation of aftercooler assembly............................................................................1295 Removal and installation of radiator guard assembly.........................................................................1296 Removal and installation of fuel tank assembly..............................................................................1301 Removal and installation of engine hood assembly............................................................................1302 Removal and installation of fan drive assembly..............................................................................1304 Removal and installation of fan motor assembly..............................................................................1306 Engine (SAA6D170E-5)............................................................................................................1309 Removal and installation of fuel supply pump assembly.......................................................................1310 Removal and installation of cylinder head assembly..........................................................................1315 Removal and installation of fuel injector assembly..........................................................................1331 Removal and installation of engine front seal...............................................................................1336 Removal and installation of engine rear seal................................................................................1338 Power train, Part 1 (Damper, power train, PTO, T/C, T/M)........................................................................1343 Removal and installation of damper assembly.................................................................................1344 Disassembly and assembly of damper..........................................................................................1348 Removal and installation of power train unit assembly.......................................................................1351 Disconnection of power train unit assembly..................................................................................1355 Connection of power train unit assembly.....................................................................................1359 Disassembly and assembly of PTO assembly....................................................................................1361 Disassembly and assembly of torque converter assembly.......................................................................1367 Disassembly and assembly of torqflow transmission assembly..................................................................1376 Power train, Part 2(Steering case, pump for power train, final drive)...........................................................1401 Disassembly and assembly of steering case assembly..........................................................................1402 Removal and installation of power train, lubrication pump assembly..........................................................1417 Removal and installation of scavenging pump assembly........................................................................1418 Removal and installation of final drive assembly............................................................................1419 Disassembly and assembly of final drive assembly............................................................................1420 Undercarriage and frame, Part 1 (Track shoe, pivot shaft, equalizer bar)........................................................1435 Removal and installation of track frame assembly............................................................................1436 Removal and installation of idler assembly..................................................................................1442 Disassembly and assembly of idler assembly..................................................................................1443 Removal and installation of recoil spring assembly..........................................................................1446 Disassembly and assembly of recoil spring assembly..........................................................................1461 Removal and installation track roller assembly..............................................................................1463 Disassembly and assembly of track roller assembly...........................................................................1468 Removal and installation of bogie assembly..................................................................................1470 Disassembly and assembly of bogie assembly..................................................................................1476 Removal and installation of 1st bogie assembly..............................................................................1478 Undercarriage and frame, Part 2(Track shoe, pivot shaft, equalizer bar).........................................................1485 Expanding and assembly track shoe installation..............................................................................1486 Whole disassembly and assembly of track shoe................................................................................1489 Dimensions table of fitting jig of link press...............................................................................1506 Disassembly and assembly of 1 link in the field.............................................................................1507 Disassembly and assembly of master link.....................................................................................1511 Removal and installation of pivot shaft assembly............................................................................1516 Removal and installation of equalizer bar...................................................................................1517 Disassembly and assembly of equalizer bar bushing...........................................................................1520 Removal and installation of segment tooth...................................................................................1522 Hydraulic system................................................................................................................1525 Removal and installation of hydraulic tank and control valve assembly.......................................................1526 Removal and installation of work equipment pump assembly....................................................................1529 Removal and installation of fan pump assembly...............................................................................1531 Removal and installation of control valve assembly..........................................................................1534 Assembly of control valve assembly..........................................................................................1536 Assembly of blade PPC valve assembly........................................................................................1542 Disassembly and assembly of ripper PPC valve assembly.......................................................................1544 Disassembly and assembly of hydraulic cylinder assembly.....................................................................1545 Disassembly and assembly of ripper pin puller cylinder assembly.............................................................1550 Work equipment..................................................................................................................1555 Removal and installation of blade assembly..................................................................................1556 Disassembly and assembly of blade assembly..................................................................................1558 Disassembly and assembly of giant ripper assembly...........................................................................1562 Cab and its attachments.........................................................................................................1567 Removal and installation of ROPS guard......................................................................................1568 Removal and installation of operator's cab assembly.........................................................................1569 Removal and installation of floor frame assembly............................................................................1573 Electrical system...............................................................................................................1579 Removal and installation of transmission and steering controller assembly...................................................1580 Removal and installation of engine controller assembly......................................................................1581 Removal and installation of VHMS controller assembly........................................................................1583 Removal and installation of air conditioner unit assembly...................................................................1584 Removal and installation of monitor panel assembly..........................................................................1587 90 Diagrams and drawings............................................................................................................ 0 Hydraulic diagrams and drawings.................................................................................................1589 Hydraulic circuit diagram (1/2).............................................................................................1591 Hydraulic circuit diagram (2/2).............................................................................................1593 Power train hydraulic circuit diagram.......................................................................................1595 Electrical diagrams and drawings................................................................................................1599 Electrical circuit diagram (1/13)...........................................................................................1601 Electrical circuit diagram (2/13)...........................................................................................1603 Electrical circuit diagram (3/13)...........................................................................................1605 Electrical circuit diagram (4/13)...........................................................................................1607 Electrical circuit diagram (5/13)...........................................................................................1609 Electrical circuit diagram (6/13)...........................................................................................1611 Electrical circuit diagram (7/13)...........................................................................................1613 Electrical circuit diagram (8/13)...........................................................................................1615 Electrical circuit diagram (9/13)...........................................................................................1617 Electrical circuit diagram (10/13)..........................................................................................1619 Electrical circuit diagram (11/13)..........................................................................................1621 Electrical circuit diagram (12/13)..........................................................................................1623 Electrical circuit diagram (13/13)..........................................................................................1625 Electrical circuit diagram for inside cab...................................................................................1627 Air conditioner unit electrical circuit diagram.............................................................................1629 Connectors table and arrangement drawing....................................................................................1631
DESCRIPTION:
KOMATSU D375A-5R BULLDOZER SHOP MANUAL SEN02424-12 – PDF DOWNLOAD
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 model 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)
A. Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
B. Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
S.S 27/12/24
