Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
KOMATSU D375A-6R BULLDOZER SHOP MANUAL SEN05214-10 – PDF DOWNLOAD
$37.95
KOMATSU D375A-6R BULLDOZER SHOP MANUAL SEN05214-10 – PDF DOWNLOAD
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
KOMATSU D375A-6R BULLDOZER SHOP MANUAL SEN05214-10 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D375A-6R BULLDOZER SHOP MANUAL SEN05214-10 – PDF DOWNLOAD
Language : English
Pages : 1788
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D375A-6R BULLDOZER SHOP MANUAL SEN05214-10 – PDF DOWNLOAD
Cover................................................................................................................................................................................................. 1 Notice of revision.................................................................................................................................................................................... 3 00 Index and Foreword................................................................................................................................................................................. 13 Table of contents................................................................................................................................................................................. 14 Table of contents............................................................................................................................................................................. 14 Foreword and general information.................................................................................................................................................................. 27 Safety notice................................................................................................................................................................................. 27 How to read the shop manual................................................................................................................................................................... 32 Explanation of terms for maintenance standard................................................................................................................................................. 34 Handling of electric equipment and hydraulic components....................................................................................................................................... 36 Handling of connectors newly used for engines................................................................................................................................................. 45 How to read electric wire code................................................................................................................................................................ 48 Precautions when carrying out work............................................................................................................................................................ 51 Method of disassembling and connecting push-pull type coupler................................................................................................................................. 54 Standard tightening torque table.............................................................................................................................................................. 57 List of Abbreviation.......................................................................................................................................................................... 61 Conversion table.............................................................................................................................................................................. 65 01 Specification...................................................................................................................................................................................... 71 Specification and technical data.................................................................................................................................................................. 73 Specification drawing......................................................................................................................................................................... 73 Specifications................................................................................................................................................................................ 74 Weight table.................................................................................................................................................................................. 79 Table of fuel, coolant and lubricants......................................................................................................................................................... 81 10 Structure and function............................................................................................................................................................................. 83 Engine and cooling system......................................................................................................................................................................... 86 Cooling system................................................................................................................................................................................ 86 Cooling fan pump.............................................................................................................................................................................. 89 Cooling fan motor............................................................................................................................................................................. 110 Power train....................................................................................................................................................................................... 116 Power train................................................................................................................................................................................... 116 Overall drawing of power train unit........................................................................................................................................................... 118 Power train hydraulic equipment arrangement drawing........................................................................................................................................... 120 Damper and universal joint.................................................................................................................................................................... 122 Torque converter and PTO...................................................................................................................................................................... 124 Torque converter control valve................................................................................................................................................................ 130 Main relief valve and torque converter relief valve........................................................................................................................................... 132 Lockup clutch ECMV and stator clutch ECMV..................................................................................................................................................... 134 Scavenging pump............................................................................................................................................................................... 139 Transmission control.......................................................................................................................................................................... 140 PCCS lever.................................................................................................................................................................................... 142 Transmission.................................................................................................................................................................................. 146 Transmission ECMV............................................................................................................................................................................. 160 Transmission lubrication relief valve......................................................................................................................................................... 165 Steering and brake control.................................................................................................................................................................... 166 Transfer unit, bevel gear shaft and steering.................................................................................................................................................. 168 Steering control valve........................................................................................................................................................................ 174 Steering clutch ECMV and Steering brake ECMV.................................................................................................................................................. 176 Parking brake valve........................................................................................................................................................................... 184 Sudden stop prevention valve.................................................................................................................................................................. 185 Final drive................................................................................................................................................................................... 187 Undercarriage and frame........................................................................................................................................................................... 192 Track frame................................................................................................................................................................................... 192 Idler cushion................................................................................................................................................................................. 194 Track roller bogie............................................................................................................................................................................ 195 Main frame.................................................................................................................................................................................... 196 Suspension.................................................................................................................................................................................... 198 Hydraulic system.................................................................................................................................................................................. 201 Work equipment hydraulic piping diagram....................................................................................................................................................... 201 PPC control piping diagram.................................................................................................................................................................... 205 Work equipment control........................................................................................................................................................................ 206 Hydraulic tank................................................................................................................................................................................ 208 Accumulator................................................................................................................................................................................... 210 PPC lock valve................................................................................................................................................................................ 211 PPC valve..................................................................................................................................................................................... 212 Piston valve.................................................................................................................................................................................. 224 Quick drop valve.............................................................................................................................................................................. 225 Pin puller switch............................................................................................................................................................................. 227 Pin puller solenoid valve..................................................................................................................................................................... 228 Blade control lever (only for the machine with dual tilt specification)....................................................................................................................... 230 Work equipment pump........................................................................................................................................................................... 232 Control valve................................................................................................................................................................................. 244 Self-pressure reducing valve.................................................................................................................................................................. 269 Work equipment.................................................................................................................................................................................... 276 Cylinder stay................................................................................................................................................................................. 276 Cab............................................................................................................................................................................................... 277 Cab mount..................................................................................................................................................................................... 277 Cab........................................................................................................................................................................................... 278 Electrical system................................................................................................................................................................................. 280 Engine control................................................................................................................................................................................ 280 Engine control system......................................................................................................................................................................... 281 CRI engine control system..................................................................................................................................................................... 290 Monitor system................................................................................................................................................................................ 292 Machine monitor............................................................................................................................................................................... 294 Lamp system................................................................................................................................................................................... 312 Engine preheat (electrical intake air heater) control......................................................................................................................................... 313 Palm command control system................................................................................................................................................................... 314 Sensor........................................................................................................................................................................................ 317 Vehicle health monitoring system (VHMS)....................................................................................................................................................... 323 ORBCOMM system................................................................................................................................................................................ 329 Pre-lubrication system........................................................................................................................................................................ 332 20 Standard value table............................................................................................................................................................................... 337 Standard service value table...................................................................................................................................................................... 339 Standard value table for engine............................................................................................................................................................... 339 Standard value table for machine.............................................................................................................................................................. 340 30 Testing and adjusting.............................................................................................................................................................................. 349 Tools for testing, adjusting and troubleshooting.................................................................................................................................................. 352 Diagnosis equipment list...................................................................................................................................................................... 352 Engine and cooling system......................................................................................................................................................................... 354 Testing engine speed.......................................................................................................................................................................... 354 Testing intake air pressure (boost pressure).................................................................................................................................................. 357 Testing exhaust temperature................................................................................................................................................................... 359 Testing exhaust gas color..................................................................................................................................................................... 362 Adjusting valve clearance..................................................................................................................................................................... 364 Measuring compression pressure................................................................................................................................................................ 366 Testing blow-by pressure...................................................................................................................................................................... 369 Testing engine oil pressure................................................................................................................................................................... 371 Handling of fuel system devices............................................................................................................................................................... 372 Releasing residual pressure from fuel system.................................................................................................................................................. 373 Testing fuel pressure......................................................................................................................................................................... 374 Handling of reduced cylinder mode operation................................................................................................................................................... 375 Handling of no injection cranking operation................................................................................................................................................... 376 Testing leakage from pressure limiter and return rate from injector........................................................................................................................... 377 Bleeding air from fuel circuit................................................................................................................................................................ 380 Testing fuel circuit for leakage.............................................................................................................................................................. 382 Replacing and adjusting alternator and air conditioner compressor belt........................................................................................................................ 383 Measuring fan speed........................................................................................................................................................................... 384 Testing fan circuit oil pressure.............................................................................................................................................................. 385 Bleeding air from fan pump.................................................................................................................................................................... 386 Adjusting fuel control dial and decelerator pedal............................................................................................................................................. 387 Power train....................................................................................................................................................................................... 390 Testing power train oil pressure.............................................................................................................................................................. 390 Adjusting transmission output speed sensor.................................................................................................................................................... 404 Simple test procedure for brake performance................................................................................................................................................... 405 Adjusting brake pedal and parking brake lever................................................................................................................................................. 406 Adjusting position of pccs lever console...................................................................................................................................................... 409 Emergency escape method when there is failure in power train.................................................................................................................................. 410 Undercarriage and frame........................................................................................................................................................................... 412 Inspecting wear of sprocket................................................................................................................................................................... 412 Testing and adjusting track shoe tension...................................................................................................................................................... 413 Hydraulic system.................................................................................................................................................................................. 414 Testing and adjusting work equipment oil pressure............................................................................................................................................. 414 Testing control circuit main pressure......................................................................................................................................................... 417 Testing PPC valve output pressure............................................................................................................................................................. 418 Adjusting play of PPC valve................................................................................................................................................................... 420 Testing output pressure of ripper pin-puller solenoid valve................................................................................................................................... 421 Checking location of cause of hydraulic drift of blade and ripper............................................................................................................................. 422 Testing leakage inside work equipment cylinder................................................................................................................................................ 423 Releasing remaining pressure in work equipment cylinders...................................................................................................................................... 424 Bleeding air from work equipment cylinders.................................................................................................................................................... 425 Adjusting ripper lever position............................................................................................................................................................... 426 Work equipment.................................................................................................................................................................................... 428 Adjusting work equipment lock lever........................................................................................................................................................... 428 Adjusting blade............................................................................................................................................................................... 429 Cab and its attachments........................................................................................................................................................................... 432 Testing and adjusting operator's cab.......................................................................................................................................................... 432 Electrical system................................................................................................................................................................................. 438 Special functions of machine monitor (EMMS)................................................................................................................................................... 438 Handling of voltage circuit of engine controller.............................................................................................................................................. 496 Adjustment method when controller has been replaced........................................................................................................................................... 497 Preparation work for troubleshooting for electrical equipment system.......................................................................................................................... 501 Inspection procedure of diode................................................................................................................................................................. 505 Handling of optional devices.................................................................................................................................................................. 506 Request for opening ORBCOMM terminal.......................................................................................................................................................... 507 Initialization procedures for VHMS controller................................................................................................................................................. 509 Using method of KOMTRAX functions of ORBCOMM terminal......................................................................................................................................... 523 Precautions for replacing VHMS controller..................................................................................................................................................... 526 Pm Clinic......................................................................................................................................................................................... 532 Pm Clinic service............................................................................................................................................................................. 532 40 Troubleshooting.................................................................................................................................................................................... 543 General information on troubleshooting............................................................................................................................................................ 552 Points to remember when troubleshooting....................................................................................................................................................... 552 Sequence of events in troubleshooting......................................................................................................................................................... 553 Checks before troubleshooting................................................................................................................................................................. 554 Classification and procedures for troubleshooting............................................................................................................................................. 579 Failure codes table........................................................................................................................................................................... 582 Classification and procedures for troubleshooting numbers..................................................................................................................................... 592 Information in troubleshooting table.......................................................................................................................................................... 594 Troubleshooting method for disconnecting wiring harness of pressure sensor system............................................................................................................. 596 Connection table for connector pin numbers.................................................................................................................................................... 599 T-branch box and T-branch adapter table....................................................................................................................................................... 635 Connector list and layout..................................................................................................................................................................... 638 Fuse locations table.......................................................................................................................................................................... 652 Troubleshooting by failurecode.................................................................................................................................................................... 656 Failure code [1380MW] Lock up clutch: Slip.................................................................................................................................................... 656 Failure code [1500L0] Transmission clutch: Abnormal........................................................................................................................................... 657 Failure code [15E0MW] Transmission clutch: Slip............................................................................................................................................... 658 Failure code [15SAL1] Forward clutch: Fill high............................................................................................................................................... 660 Failure code [15SALH] Forward clutch: Fill Low................................................................................................................................................ 662 Failure code [15SBL1] Reverse clutch: Fill high............................................................................................................................................... 664 Failure code [15SBLH] Reverse clutch: Fill Low................................................................................................................................................ 666 Failure code [15SEL1] Speed 1st clutch: Fill high............................................................................................................................................. 668 Failure code [15SELH] Speed 1st clutch: Fill Low.............................................................................................................................................. 670 Failure code [15SFL1] Speed 2nd clutch: Fill high............................................................................................................................................. 672 Failure code [15SFLH] Speed 2nd clutch: Fill Low.............................................................................................................................................. 674 Failure code [15SGL1] Speed 3rd clutch: Fill high............................................................................................................................................. 676 Failure code [15SGLH] Speed 3rd clutch: Fill Low.............................................................................................................................................. 678 Failure code [15SJL1] L/U: Fill high.......................................................................................................................................................... 680 Failure code [15SJLH] L/U: Fill low........................................................................................................................................................... 682 Failure code [1800MW] P/T clutch: Slip........................................................................................................................................................ 684 Failure code [2201L1] Right clutch: Fill high................................................................................................................................................. 686 Failure code [2201LH] Right clutch: Fill low.................................................................................................................................................. 688 Failure code [2202L1] Left clutch: Fill high.................................................................................................................................................. 690 Failure code [2202LH] Left clutch: Fill low................................................................................................................................................... 692 Failure code [2300NR] Brake Themal Load Abnormality........................................................................................................................................... 694 Failure code [2301L1] Right brake: Fill high.................................................................................................................................................. 696 Failure code [2301LH] Right brake: Fill low................................................................................................................................................... 698 Failure code [2301NR] Steering Brake RH Themal Load Abnormality............................................................................................................................... 700 Failure code [2302L1] Left brake: Fill high................................................................................................................................................... 702 Failure code [2302LH] Left brake: Fill low.................................................................................................................................................... 704 Failure code [2302NR] Steering Brake LH Themal Load Abnormality............................................................................................................................... 706 Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection........................................................................................................................................ 708 Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit........................................................................................................................................ 710 Failure code [AA10NX] Air Cleaner Clogging.................................................................................................................................................... 712 Failure code [AB00MA] Battery Charge Abnormal................................................................................................................................................. 714 Failure code [B@BAZG] Eng Oil Press Low....................................................................................................................................................... 715 Failure code [B@BAZK] Eng Oil Level Low....................................................................................................................................................... 716 Failure code [B@BCNS] Eng Water Overheat...................................................................................................................................................... 717 Failure code [B@BCZK] Eng Water Level Low..................................................................................................................................................... 718 Failure code [B@CENS] T/C Oil Overheat........................................................................................................................................................ 719 Failure code [B@HANS] Hyd Oil Overheat........................................................................................................................................................ 720 Failure code [B@HAZK] Hyd Oil Level Low....................................................................................................................................................... 721 Failure code [CA111] ECM Critical Internal Failure............................................................................................................................................ 722 Failure code [CA115] Eng Ne and Bkup Speed Sens Error......................................................................................................................................... 724 Failure code [CA122] Chg Air Press Sensor High Error.......................................................................................................................................... 726 Failure code [CA123] Chg Air Press Sensor Low Error........................................................................................................................................... 728 Failure code [CA131] Throttle Sensor High Error............................................................................................................................................... 730 Failure code [CA132] Throttle Sensor Low Error................................................................................................................................................ 732 Failure code [CA135] Eng Oil Press Sensor High Error.......................................................................................................................................... 734 Failure code [CA141] Eng Oil Press Sensor Low Error........................................................................................................................................... 736 Failure code [CA144] Coolant Temp Sens High Error............................................................................................................................................. 738 Failure code [CA145] Coolant Temp Sens Low Error.............................................................................................................................................. 740 Failure code [CA153] Chg Air Temp Sensor High Error........................................................................................................................................... 742 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................................................................................................ 744 Failure code [CA187] Sens Supply 2 Volt Low Error............................................................................................................................................. 746 Failure code [CA212] Eng Oil Temp Sensor High Error........................................................................................................................................... 748 Failure code [CA213] Eng Oil Temp Sensor Low Error............................................................................................................................................ 750 Failure code [CA221] Ambient Press Sens High Error............................................................................................................................................ 752 Failure code [CA222] Ambient Press Sens Low Error............................................................................................................................................. 754 Failure code [CA227] Sens Supply 2 Volt High Error............................................................................................................................................ 756 Failure code [CA234] Eng Overspeed............................................................................................................................................................ 757 Failure code [CA238] Ne Speed Sens Supply Volt Error.......................................................................................................................................... 758 Failure code [CA263] Fuel Temp Sensor High Error.............................................................................................................................................. 760 Failure code [CA265] Fuel Temp Sensor Low Error............................................................................................................................................... 762 Failure code [CA271] IMV/PCV1 Short Error..................................................................................................................................................... 764 Failure code [CA272] IMV/PCV1 Open Error...................................................................................................................................................... 765 Failure code [CA273] PCV2 Short Error......................................................................................................................................................... 766 Failure code [CA274] PCV2 Open Error.......................................................................................................................................................... 767 Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................................................................................................ 768 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................................................................................................ 770 Failure code [CA324] Inj #3 (L#3) Open/Short Error............................................................................................................................................ 772 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................................................................................................ 774 Failure code [CA331] Inj #2 (L#2) Open/Short Error............................................................................................................................................ 776 Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................................................................................................................ 778 Failure code [CA342] Calibration Code Incompatibility......................................................................................................................................... 780 Failure code [CA351] Injectors Drive Circuit Error............................................................................................................................................ 781 Failure code [CA352] Sens Supply 1 Volt Low Error............................................................................................................................................. 782 Failure code [CA386] Sens Supply 1 Volt High Error............................................................................................................................................ 784 Failure code [CA441] Battery Voltage Low Error................................................................................................................................................ 785 Failure code [CA442] Battery Voltage High Error............................................................................................................................................... 786 Failure code [CA449] Rail Press Very High Error............................................................................................................................................... 787 Failure code [CA451] Rail Press Sensor High Error............................................................................................................................................. 788 Failure code [CA452] Rail Press Sensor Low Error.............................................................................................................................................. 790 Failure code [CA553] Rail Press High Error.................................................................................................................................................... 792 Failure code [CA554] Rail Press Sensor In Range Error......................................................................................................................................... 793 Failure code [CA559] Rail Press Low Error..................................................................................................................................................... 794 Failure code [CA689] Eng Ne Speed Sensor Error................................................................................................................................................ 798 Failure code [CA731] Eng Bkup Speed Sens Phase Error.......................................................................................................................................... 800 Failure code [CA757] All Continuous Data Lost Error........................................................................................................................................... 801 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................................................................................................. 802 Failure code [CA1633] KOMNET Datalink Timeout Error........................................................................................................................................... 804 Failure code [CA2185] Throt Sens Sup Volt High Error.......................................................................................................................................... 805 Failure code [CA2186] Throt Sens Sup Volt Low Error........................................................................................................................................... 806 Failure code [CA2249] Rail Press Very Low Error............................................................................................................................................... 807 Failure code [D110KB] Battery Relay: Drive Short Circuit...................................................................................................................................... 808 Failure code [D130KA] Neutral relay: Disconnection............................................................................................................................................ 810 Failure code [D130KB] Neutral relay: Short circuit............................................................................................................................................ 812 Failure code [D161KA] Back-up alarm releay: Disconnection..................................................................................................................................... 814 Failure code [D161KB] Back-up alarm releay: Short circuit..................................................................................................................................... 816 Failure code [D182KZ] Preheater Relay Abnormality............................................................................................................................................. 818 Failure code [D190KA] ACC signal relay: Disconnection......................................................................................................................................... 820 Failure code [D190KB] ACC signal relay: Short circuit......................................................................................................................................... 822 Failure code [D1EFKA] Pre lub. motor relay: Disconnection..................................................................................................................................... 824 Failure code [D1EFKB] Pre lub. motor relay: Short circuit..................................................................................................................................... 826 Failure code [DAFRKR] Monitor: Can communication lost (PT).................................................................................................................................... 828 Failure code [dAFRKR] Monitor: CAN communication lost (WE).................................................................................................................................... 829 Failure code [DAFRMC] CAN Discon (Monitor Detected)........................................................................................................................................... 830 Failure code [DB2RKR] ENG cont.: Can communication lost (PT).................................................................................................................................. 836 Failure code [dB2RKR] ENG controller: CAN communication lost (WE)............................................................................................................................. 840 Failure code [DB90KT] WE controller: Abnormality in controller................................................................................................................................ 841 Failure code [DB91KK] WE controller: Source voltage reduction................................................................................................................................. 842 Failure code [DB92KK] WE controller: Output voltage reduction................................................................................................................................. 844 Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction.............................................................................................................................. 846 Failure code [DB99KQ] WE controller: Type select signal....................................................................................................................................... 848 Failure code [DB9RKR] WE controller: Can communication lost (PT).............................................................................................................................. 849 Failure code [DBB0KK] VHMS controller:Source voltage reduction................................................................................................................................ 852 Failure code [DBB0KQ] VHMS connector connection abnormality................................................................................................................................... 854 Failure code [DBB3KK] VHMS controller: Source voltage reduction............................................................................................................................... 855 Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction.................................................................................................................................. 858 Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction................................................................................................................................... 860 Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction................................................................................................................................... 862 Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)................................................................................................................................. 864 Failure code [DBE0KT] PT controller: Abnormality in controller................................................................................................................................ 865 Failure code [DBE1KK] PT controller: Source voltage reduction................................................................................................................................. 866 Failure code [DBE2KK] PT controller: Output voltage reduction................................................................................................................................. 868 Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction.............................................................................................................................. 870 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction.................................................................................................................................. 872 Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction.................................................................................................................................. 874 Failure code [DBE9KQ] PT controller: Type select signal....................................................................................................................................... 876 Failure code [DBERKR] PT controller: Can communication lost (WE).............................................................................................................................. 877 Failure code [DD12KA] Shift up Sw: Disconnection.............................................................................................................................................. 880 Failure code [DD12KB] Shift up Sw: Short circuit.............................................................................................................................................. 882 Failure code [DD13KA] Shift down Sw: Disconnection............................................................................................................................................ 884 Failure code [DD13KB] Shift down Sw: Short circuit............................................................................................................................................ 886 Failure code [DD14KA] Parking lever Sw: Dissconnection........................................................................................................................................ 888 Failure code [DD14KB] Parking lever Sw: Short circuit......................................................................................................................................... 890 Failure code [DDB9L4] Reverse SW Signal disagreement.......................................................................................................................................... 892 Failure code [DDE2KA] Pre lub. oil press sw: Disconnection.................................................................................................................................... 894 Failure code [DDK3L4] Forward SW Signal disagreement.......................................................................................................................................... 896 Failure code [DDK5KA] Shift switch disconnection.............................................................................................................................................. 898 Failure code [DDK5KB] Shift switch short circuit.............................................................................................................................................. 900 Failure code [DDN2LD] Blade tilt RH pressure SW abnormality................................................................................................................................... 902 Failure code [DDN3LD] Blade tilt LH pressure SW abnormality................................................................................................................................... 904 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection....................................................................................................................................... 906 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit....................................................................................................................................... 908 Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection......................................................................................................................................... 910 Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit......................................................................................................................................... 912 Failure code [DDNALD] Blade lift up pressure SW abnormality................................................................................................................................... 914 Failure code [DDNBLD] Ripper lift up pressure SW abnormality.................................................................................................................................. 916 Failure code [DDNCLD] Ripper lift down pressure SW abnormality................................................................................................................................ 918 Failure code [DDNDLD] Ripper tilt in pressure SW abnormality.................................................................................................................................. 920 Failure code [DDNELD] Ripper tilt back pressure SW abnormality................................................................................................................................ 922 Failure code [DDNFLD] Blade lift down pressure SW abnormality................................................................................................................................. 924 Failure code [DDNLKA] Weq lock Sw: Disconnection.............................................................................................................................................. 926 Failure code [DDNLKB] Weq lock Sw: Short circuit.............................................................................................................................................. 928 Failure code [DDT5KA] Neutral switch disconnection............................................................................................................................................ 930 Failure code [DDT5KB] Neutral switch short circuit............................................................................................................................................ 932 Failure code [DDT5KQ] Lever SPEC selection signal disagreement................................................................................................................................ 934 Failure code [DDTSL1] S/C: Fill high.......................................................................................................................................................... 936 Failure code [DDTSLH] S/C: Fill low........................................................................................................................................................... 938 Failure code [DGE5KX] Ambient temp sensor abnormality......................................................................................................................................... 940 Failure code [DGS1KX] Hyd oil temp: signal abnormal........................................................................................................................................... 942 Failure code [DGT1KA] T/C oil temp sensor: Abnormal........................................................................................................................................... 944 Failure code [DGT1KX] T/C oil temp sensor: Abnormal........................................................................................................................................... 946 Failure code [DGT5KA] F exhaust temp sensor disconnection..................................................................................................................................... 948 Failure code [DGT5KB] F exhaust temp sensor short circuit..................................................................................................................................... 950 Failure code [DGT6KA] R exhaust temp sensor disconnection..................................................................................................................................... 952 Failure code [DGT6KB] R exhaust temp sensor short circuit..................................................................................................................................... 954 Failure code [DH21KA] Weq pressure sensor: Disconnection...................................................................................................................................... 956 Failure code [DH21KB] Weq pressure sensor: Short circuit...................................................................................................................................... 958 Failure code [DHE5KB] ENG blow-by pressure sensor disconnection............................................................................................................................... 960 Failure code [DHE5KY] ENG blow-by pressure sensor short circuit............................................................................................................................... 962 Failure code [DHT3KX] T/M oil pressure sensor abnormality..................................................................................................................................... 964 Failure code [DHT5KA] T/C in-pressure sensor: Disconnection................................................................................................................................... 966 Failure code [DHT5KB] T/C in-pressure sensor: Short circuit................................................................................................................................... 968 Failure code [DHT7KA] T/C out-pressure sensor: Disconnection.................................................................................................................................. 970 Failure code [DHT7KB] T/C out-pressure sensor: Short circuit.................................................................................................................................. 972 Failure code [DK10KA] Fuel control Dial: Disconnection........................................................................................................................................ 974 Failure code [DK10KB] Fuel control Dial: Short circuit........................................................................................................................................ 976 Failure code [DK30KA] ST lever 1: Disconnection............................................................................................................................................... 978 Failure code [DK30KB] ST lever 1: Short circuit............................................................................................................................................... 980 Failure code [DK30KX] ST lever: Out of normal range........................................................................................................................................... 982 Failure code [DK30KZ] ST lever: Disconnection or short circuit................................................................................................................................ 983 Failure code [DK30L8] ST lever: Signal mismatch............................................................................................................................................... 984 Failure code [DK31KA] ST lever 2: Disconnection............................................................................................................................................... 986 Failure code [DK31KB] ST lever 2: Short circuit............................................................................................................................................... 988 Failure code [DK40KA] Brake potentiometer: Disconnection...................................................................................................................................... 990 Failure code [DK40KB] Brake potentiometer: Short circuit...................................................................................................................................... 992 Failure code [DK55KX] FR lever: Out of normal range........................................................................................................................................... 994 Failure code [DK55KZ] FR lever: Disconnection or short circuit................................................................................................................................ 995 Failure code [DK55L8] FR lever: Signal mismatch............................................................................................................................................... 996 Failure code [DK56KA] FR lever 1: Disconnection............................................................................................................................................... 998 Failure code [DK56KB] FR lever 1: Short circuit...............................................................................................................................................1000 Failure code [DK57KA] FR lever 2: Disconnection...............................................................................................................................................1002 Failure code [DK57KB] FR lever 2: Short circuit...............................................................................................................................................1004 Failure code [DK60KA] Acceleration sensor: Disconnection......................................................................................................................................1006 Failure code [DK60KB] Acceleration sensor: Short circuit......................................................................................................................................1008 Failure code [DKH1KA] Pitch angle sensor: Disconnection.......................................................................................................................................1010 Failure code [DKH1KB] Pitch angle sensor: Short circuit.......................................................................................................................................1012 Failure code [DLF1KA] T/C out-speed sensor: Disconnection.....................................................................................................................................1014 Failure code [DLM3KA] Fan rev. sensor: Disconnection..........................................................................................................................................1016 Failure code [DLM3MB] Fan control: Decline....................................................................................................................................................1018 Failure code [DLT3KA] T/M out-speed sensor: Disconnection.....................................................................................................................................1019 Failure code [DLT3KB] T/M out-speed sensor: Abnormal..........................................................................................................................................1020 Failure code [DW59KA] Blade dual selector SOL disconnection...................................................................................................................................1021 Failure code [DW59KB] Blade dual selector SOL short circuit...................................................................................................................................1022 Failure code [DW59KY] Blade dual selector SOL hot short.......................................................................................................................................1024 Failure code [DW5AKA] Blade pitch selector SOL disconnection..................................................................................................................................1026 Failure code [DW5AKB] Blade pitch selector SOL short circuit..................................................................................................................................1027 Failure code [DW5AKY] Blade pitch selector SOL Short circuit..................................................................................................................................1028 Failure code [DW7BKA] Fan rev EPC: Disconnection..............................................................................................................................................1030 Failure code [DW7BKB] Fan rev EPC: Short circuit..............................................................................................................................................1031 Failure code [DWN3KA] Ssp solenoid: Disconnection.............................................................................................................................................1032 Failure code [DWN3KB] Ssp solenoid: Short circuit.............................................................................................................................................1034 Failure code [DWN3KY] SSP solenoid: Short circuit.............................................................................................................................................1036 Failure code [DWN5KA] Fan pump solenoid 1: Disconnection......................................................................................................................................1038 Failure code [DWN5KB] Fan pump solenoid 1: Short circuit......................................................................................................................................1040 Failure code [DWN5KY] Fan pump solenoid 1: Short circuit......................................................................................................................................1042 Failure code [DWNCKA] Fan pump solenoid 2: Disconnection......................................................................................................................................1044 Failure code [DWNCKB] Fan pump solenoid 2: Short circuit......................................................................................................................................1046 Failure code [DWNCKY] Fan pump solenoid 2: Short circuit......................................................................................................................................1048 Failure code [DXH1KA] Lock-up ECMV: Disconnection.............................................................................................................................................1050 Failure code [DXH1KB] Lock-up ECMV: Short circuit.............................................................................................................................................1051 Failure code [DXH1KY] Lock-up ECMV: Short circuit.............................................................................................................................................1052 Failure code [DXH4KA] 1st clutch ECMV: Disconnection..........................................................................................................................................1054 Failure code [DXH4KB] 1st clutch ECMV: Short circuit..........................................................................................................................................1056 Failure code [DXH4KY] 1st clutch ECMV: Short circuit..........................................................................................................................................1058 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection..........................................................................................................................................1060 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit..........................................................................................................................................1062 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit..........................................................................................................................................1064 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection..........................................................................................................................................1066 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit..........................................................................................................................................1068 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit..........................................................................................................................................1070 Failure code [DXH7KA] R clutch ECMV: Disconnection............................................................................................................................................1072 Failure code [DXH7KB] R clutch ECMV: Short circuit............................................................................................................................................1074 Failure code [DXH7KY] R clutch ECMV: Short circuit............................................................................................................................................1076 Failure code [DXH8KA] F clutch ECMV: Disconnection............................................................................................................................................1078 Failure code [DXH8KB] F clutch ECMV: Short circuit............................................................................................................................................1080 Failure code [DXH8KY] F clutch ECMV: Short circuit............................................................................................................................................1082 Failure code [DXH9KA] Right clutch ECMV: Disconnection........................................................................................................................................1084 Failure code [DXH9KB] Right clutch ECMV: Short circuit........................................................................................................................................1086 Failure code [DXH9KY] Right clutch ECMV: Short circuit........................................................................................................................................1088 Failure code [DXHAKA] Left clutch ECMV: Disconnection.........................................................................................................................................1090 Failure code [DXHAKB] Left clutch ECMV: Short circuit.........................................................................................................................................1092 Failure code [DXHAKY] Left clutch ECMV: Short circuit.........................................................................................................................................1094 Failure code [DXHBKA] Right brake ECMV: Disconnection.........................................................................................................................................1096 Failure code [DXHBKB] Right brake ECMV: Short circuit.........................................................................................................................................1098 Failure code [DXHBKY] Right brake ECMV: Short circuit.........................................................................................................................................1100 Failure code [DXHCKA] Left brake ECMV: Disconnection..........................................................................................................................................1102 Failure code [DXHCKB] Left brake ECMV: Short circuit..........................................................................................................................................1104 Failure code [DXHCKY] Left brake ECMV: Short circuit..........................................................................................................................................1106 Failure code [DXJBKA] S/C ECMV: Disconnection.................................................................................................................................................1108 Failure code [DXJBKB] S/C ECMV: Short circuit.................................................................................................................................................1109 Failure code [DXJBKY] S/C ECMV: Short circuit.................................................................................................................................................1110 Failure code [DY2HKA] Pre lub. motor: Disconnection...........................................................................................................................................1112 Failure code [F@BBZL] ENG blow-by pressure high level.........................................................................................................................................1114 Failure code [F@BYNR] F exhaust temp high level (2)...........................................................................................................................................1115 Failure code [F@BYNS] F exhaust temp high level (1)...........................................................................................................................................1116 Failure code [F@BZNR] R exhaust temp high level (2)...........................................................................................................................................1117 Failure code [F@BZNS] R exhaust temp high level (1)...........................................................................................................................................1118 Troubleshooting of electrical system (E-mode).....................................................................................................................................................1120 Information contained in troubleshooting table................................................................................................................................................1120 E-1 Engine does not start (starting motor does not turn)......................................................................................................................................1122 E-2 Preheater does not operate................................................................................................................................................................1126 E-3 When starting switch is turned ON, machine monitor displays nothing.......................................................................................................................1130 E-4 When starting switch is turned ON (before starting engine), basic check item lights up....................................................................................................1134 E-5 Precaution item lights up while engine is running.........................................................................................................................................1136 E-6 Emergency stop item lights up while engine is running.....................................................................................................................................1138 E-7 Engine coolant temperature gauge does not indicate normally...............................................................................................................................1139 E-8 Fuel gauge does not indicate properly.....................................................................................................................................................1140 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally................................................................................................................1142 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally.....................................................................................................................1143 E-11 Contents of display by machine monitor are different from applicable machine.............................................................................................................1144 E-12 Machine monitor does not display some items..............................................................................................................................................1144 E-13 Function switch does not work............................................................................................................................................................1144 E-14 Operation mode does not change...........................................................................................................................................................1145 E-15 Gearshift mode does not change...........................................................................................................................................................1145 E-16 Customize function does not operate normally.............................................................................................................................................1146 E-17 Customize memory function does not operate normally......................................................................................................................................1146 E-18 Alarm buzzer does not sound or does not stop.............................................................................................................................................1147 E-19 When starting switch is turned OFF, service meter is not displayed.......................................................................................................................1147 E-20 Machine monitor cannot be set in service mode............................................................................................................................................1147 E-21 The ripper pin puller cylinder does not operate..........................................................................................................................................1148 E-22 Horn does not sound or does not stop.....................................................................................................................................................1150 E-23 Back-up alarm does not sound or does not stop............................................................................................................................................1152 E-24 Fan does not reverse.....................................................................................................................................................................1154 E-25 The head lamp and rear lamp do not light up..............................................................................................................................................1155 E-26 Windshield wiper does not operate........................................................................................................................................................1164 E-27 Window washer does not operate...........................................................................................................................................................1172 E-28 Electric priming pump does not operate or does not stop automatically....................................................................................................................1180 E-29 Orbcomm terminal does not operate normally (Data are not transmitted)....................................................................................................................1182 E-30 Gear cannot be shifted...................................................................................................................................................................1184 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................................................................1186 Information in troubleshooting table..........................................................................................................................................................1186 List of Failure Modes and Causes..............................................................................................................................................................1188 H-1 Machine lacks power(or drawbar pull)......................................................................................................................................................1190 H-2 Machine cannot travel (at 2nd or 3rd each speed)..........................................................................................................................................1192 H-3 Machine cannot travel at any gear speeds..................................................................................................................................................1193 H-4 Machine travels only in one direction, forward or reverse.................................................................................................................................1195 H-5 Large time lag at gear shifting or directional change.....................................................................................................................................1196 H-6 Machine connot turn.......................................................................................................................................................................1197 H-7 Machine turns only to one side............................................................................................................................................................1198 H-8 Machine overruns at turnning..............................................................................................................................................................1199 H-9 Brake does not work.......................................................................................................................................................................1200 H-10 Torque converter does not lock up........................................................................................................................................................1201 H-11 Power train oil overheats................................................................................................................................................................1202 H-12 All work equipment operates too slow or lacks power......................................................................................................................................1203 H-13 All work equipment does not operate......................................................................................................................................................1204 H-14 Blade lift cylinder speed is too slow or lacks power.....................................................................................................................................1205 H-15 Blade tilt cylinder speed is too slow or lacks power.....................................................................................................................................1206 H-16 Ripper lift cylinder speed is too slow or lacks power....................................................................................................................................1207 H-17 Ripper tilt cylinder speed is too slow or lacks power....................................................................................................................................1208 H-18 Excessive hydraulic drift of blade lift cylinder.........................................................................................................................................1209 H-19 Excessive hydraulic drift of blade tilt cylinder.........................................................................................................................................1210 H-20 Excessive hydraulic drift of ripper lift cylinder........................................................................................................................................1211 H-21 Ripper pin puller cylinder does not operate (machine with giant ripper)..................................................................................................................1212 H-22 Blade pitch does not work (machine with dual tilt specification).........................................................................................................................1213 H-23 Abnormal noise from around work equipment pump...........................................................................................................................................1214 H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)...................................................................................................1215 Troubleshooting of engine (S-mode)................................................................................................................................................................1216 Method of using troubleshooting chart.........................................................................................................................................................1216 S-1 Engine does not start easily..............................................................................................................................................................1220 S-2 Engine does not start.....................................................................................................................................................................1221 S-3 Engine does not rev up smoothly (response-up is poor).....................................................................................................................................1224 S-4 Engine stops during operation.............................................................................................................................................................1225 S-5 Engine does not rotate smoothly (hunting).................................................................................................................................................1226 S-6 Engine lacks power (or output shortage)...................................................................................................................................................1227 S-7 Exhaust smoke is black (Incomplete combustion)............................................................................................................................................1228 S-8 Oil is consumption is excessive(or exhaust smoke is blue).................................................................................................................................1229 S-9 Engine oil becomes contaminated quickly...................................................................................................................................................1230 S-10 Fuel consumption is excessive............................................................................................................................................................1231 S-11 Oil mixes into coolant(coolant blows back or is reduced).................................................................................................................................1232 S-12 Engine pressure monitor lights up (drop in engine oil pressure)..........................................................................................................................1233 S-13 Oil level rises (Coolant or fuel mixes into oil).........................................................................................................................................1234 S-14 Coolant temperature rises too high (overheating).........................................................................................................................................1235 S-15 Abnormal noise is heard..................................................................................................................................................................1236 S-16 Vibration is excessive...................................................................................................................................................................1237 S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but stalls)....1238 50 Disassembly and assembly...........................................................................................................................................................................1241 General information on disassembly and assembly...................................................................................................................................................1244 How to read this manual.......................................................................................................................................................................1244 Coating materials list........................................................................................................................................................................1246 Special tool list.............................................................................................................................................................................1249 Sketches of special tools.....................................................................................................................................................................1257 Engine and cooling system.........................................................................................................................................................................1265 Removal and installation of fuel supply pump assembly.........................................................................................................................................1265 Removal and installation of fuel injector assembly............................................................................................................................................1270 Removal and installation of cylinder head assembly............................................................................................................................................1275 Removal and installation of radiator guard assembly...........................................................................................................................................1290 Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)...............................................................................................1295 Removal and installation of radiator..........................................................................................................................................................1300 Removal and installation of hydraulic oil cooler..............................................................................................................................................1302 Removal and installation of aftercooler.......................................................................................................................................................1303 Removal and installation of engine assembly...................................................................................................................................................1304 Removal and installation of engine hood assembly..............................................................................................................................................1311 Removal and installation of engine front seal.................................................................................................................................................1314 Removal and installation of engine rear seal..................................................................................................................................................1316 Removal and installation of fan drive assembly................................................................................................................................................1320 Removal and installation of fan motor assembly................................................................................................................................................1322 Removal and installation of fuel tank assembly................................................................................................................................................1324 Power train.......................................................................................................................................................................................1326 Removal and installation of damper assembly...................................................................................................................................................1326 Disassembly and assembly of damper assembly...................................................................................................................................................1330 Removal and installation of power train unit assembly.........................................................................................................................................1333 Disconnection and connection of power train unit assembly.....................................................................................................................................1339 Disassembly and assembly of PTO assembly......................................................................................................................................................1348 Disassembly and assembly of torque converter assembly.........................................................................................................................................1354 Disassembly and assembly of TORQFLOW transmission assembly....................................................................................................................................1363 Disassembly and assembly of steering case assembly............................................................................................................................................1390 Removal and installation of power train pump and lubrication pump assembly....................................................................................................................1406 Removal and installation of scavenging pump assembly..........................................................................................................................................1407 Removal and installation of final drive assembly..............................................................................................................................................1408 Disassembly and assembly of final drive assembly..............................................................................................................................................1410 Undercarriage and frame...........................................................................................................................................................................1423 Removal and installation of track frame assembly..............................................................................................................................................1423 Removal and installation of idler assembly....................................................................................................................................................1428 Disassembly and assembly of idler assembly....................................................................................................................................................1429 Removal and installation of recoil spring assembly............................................................................................................................................1433 Disassembly and assembly of recoil spring assembly............................................................................................................................................1438 Removal and installation of track roller assembly.............................................................................................................................................1440 Disassembly and assembly of track roller assembly.............................................................................................................................................1443 Removal and installation of carrier roller assembly...........................................................................................................................................1446 Disassembly and assembly of carrier roller assembly...........................................................................................................................................1447 Removal and installation of bogie assembly....................................................................................................................................................1451 Disassembly and assembly of bogie assembly....................................................................................................................................................1456 Removal and installation of first bogie assembly..............................................................................................................................................1458 Separation and connection of track shoe assembly..............................................................................................................................................1463 Overall disassembly and assembly of track shoe................................................................................................................................................1467 Link press press-fitting jig dimensions.......................................................................................................................................................1484 Disassembly and assembly of one link assembly in the field....................................................................................................................................1485 Disassembly and assembly of master link.......................................................................................................................................................1490 Removal and installation of pivot shaft assembly..............................................................................................................................................1494 Removal and installation of equalizer bar.....................................................................................................................................................1495 Disassembly and assembly of equalizer bar bushing.............................................................................................................................................1499 Removal and installation of segment tooth.....................................................................................................................................................1501 Hydraulic system..................................................................................................................................................................................1502 Removal and installation of hydraulic tank assembly...........................................................................................................................................1502 Removal and installation of work equipment pump assembly......................................................................................................................................1505 Removal and installation of fan pump assembly.................................................................................................................................................1509 Removal and installation of control valve assembly............................................................................................................................................1511 Disassembly and assembly of control valve assembly............................................................................................................................................1513 Disassembly and assembly of blade PPC valve assembly..........................................................................................................................................1518 Disassembly and assembly of ripper PPC valve assembly.........................................................................................................................................1521 Disassembly and assembly of hydraulic cylinder assembly.......................................................................................................................................1523 Disassembly and assembly of ripper pin puller cylinder assembly...............................................................................................................................1531 Work equipment....................................................................................................................................................................................1534 Removal and installation of blade assembly....................................................................................................................................................1534 Disassembly and assembly of blade assembly....................................................................................................................................................1536 Disassembly and assembly of giant ripper assembly.............................................................................................................................................1540 Cab and its attachments...........................................................................................................................................................................1543 Removal and installation of ROPS guard........................................................................................................................................................1543 Removal and installation of operator's cab assembly...........................................................................................................................................1544 Removal and installation of floor frame assembly..............................................................................................................................................1548 Removal and installation of air conditioner unit assembly.....................................................................................................................................1552 Electrical system.................................................................................................................................................................................1559 Removal and installation of transmission controller assembly and steering controller assembly.................................................................................................1559 Removal and installation of engine controller assembly........................................................................................................................................1560 Removal and installation of VHMS controller assembly..........................................................................................................................................1562 Removal and installation of machine monitor assembly..........................................................................................................................................1563 60 Maintenance Standard...............................................................................................................................................................................1565 Engine and cooling system.........................................................................................................................................................................1567 Engine mount..................................................................................................................................................................................1567 Cooling fan pump..............................................................................................................................................................................1569 Cooling fan motor.............................................................................................................................................................................1576 Power train.......................................................................................................................................................................................1578 Power train unit..............................................................................................................................................................................1578 Damper and universal joint....................................................................................................................................................................1580 Torque converter and PTO......................................................................................................................................................................1583 Main relief valve and torque converter relief valve...........................................................................................................................................1586 Lockup clutch ECMV and stator clutch ECMV.....................................................................................................................................................1587 Scavenging pump...............................................................................................................................................................................1588 Transmission control..........................................................................................................................................................................1589 Transmission..................................................................................................................................................................................1590 Transmission lubricating oil relief valve.....................................................................................................................................................1595 Power train and lubrication pump..............................................................................................................................................................1596 Transfer, bevel gear shaft and steering unit..................................................................................................................................................1598 Steering control valve........................................................................................................................................................................1604 Steering clutch ECMV and steering brake ECMV..................................................................................................................................................1605 Parking brake valve...........................................................................................................................................................................1606 Final drive...................................................................................................................................................................................1607 Sprocket......................................................................................................................................................................................1610 Undercarriage and frame...........................................................................................................................................................................1612 Track frame...................................................................................................................................................................................1612 Idler cushion.................................................................................................................................................................................1614 Idler.........................................................................................................................................................................................1616 Track roller..................................................................................................................................................................................1618 Carrier roller................................................................................................................................................................................1620 Track roller bogie............................................................................................................................................................................1621 Track shoe....................................................................................................................................................................................1622 Main frame....................................................................................................................................................................................1626 Suspension....................................................................................................................................................................................1628 Hydraulic system..................................................................................................................................................................................1632 PPC valve.....................................................................................................................................................................................1632 Hydraulic cylinder............................................................................................................................................................................1638 Quick drop valve..............................................................................................................................................................................1641 Work equipment pump...........................................................................................................................................................................1642 Control valve.................................................................................................................................................................................1645 Self-pressure reducing valve..................................................................................................................................................................1658 Work equipment....................................................................................................................................................................................1661 Cylinder stay.................................................................................................................................................................................1661 Blade.........................................................................................................................................................................................1662 Cutting edge and end bit......................................................................................................................................................................1666 Ripper........................................................................................................................................................................................1668 80 Appendix...........................................................................................................................................................................................1671 Air conditioner...................................................................................................................................................................................1673 Precautions for refrigerant...................................................................................................................................................................1673 Air conditioner component.....................................................................................................................................................................1674 Configuration and function of refrigeration cycle.............................................................................................................................................1676 Outline of refrigeration cycle................................................................................................................................................................1677 Air conditioner unit..........................................................................................................................................................................1680 Blower unit...................................................................................................................................................................................1684 FRESH/RECIRC air changeover damper............................................................................................................................................................1685 Compressor....................................................................................................................................................................................1686 Condenser.....................................................................................................................................................................................1687 Receiver drier................................................................................................................................................................................1688 Air conditioner control panel.................................................................................................................................................................1690 Procedure for testing and troubleshooting.....................................................................................................................................................1692 Circuit diagram and arrangement of connector pins.............................................................................................................................................1694 System diagram................................................................................................................................................................................1696 Parts and connectors layout...................................................................................................................................................................1698 Testing temperature control...................................................................................................................................................................1702 Testing FRESH/RECIC air changeover............................................................................................................................................................1703 Testing relay.................................................................................................................................................................................1704 Troubleshooting chart 1.......................................................................................................................................................................1706 Troubleshooting chart 2.......................................................................................................................................................................1708 Information in troubleshooting table..........................................................................................................................................................1710 Troubleshooting for power supply system (Air conditioner does not operate)....................................................................................................................1712 Troubleshooting for compressor system (Air is not cooled).....................................................................................................................................1714 Troubleshooting for blower motor system (Air does not come out or air flow is abnormal).......................................................................................................1718 Troubleshooting for temperature control.......................................................................................................................................................1724 Troubleshooting for FRESH/RECIRC air changeover...............................................................................................................................................1726 Troubleshooting with gauge pressure...........................................................................................................................................................1728 Connection of service tool....................................................................................................................................................................1730 Precautions for disconnecting and connecting..................................................................................................................................................1732 Handling of compressor oil....................................................................................................................................................................1734 90 Diagrams and Drawings..............................................................................................................................................................................1737 Hydraulic diagrams and drawings...................................................................................................................................................................1739 Symbols used in hydraulic circuit diagrams....................................................................................................................................................1739 Power train hydraulic circuit diagram.........................................................................................................................................................1741 Hydraulic circuit diagram.....................................................................................................................................................................1743 Electrical diagrams and drawings..................................................................................................................................................................1747 Symbols used in electrical circuit diagrams...................................................................................................................................................1747 Electrical circuit diagram....................................................................................................................................................................1751 Index.................................................................................................................................................................................................1779
DESCRIPTION:
KOMATSU D375A-6R BULLDOZER SHOP MANUAL SEN05214-10 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear the safety glasses when hitting parts with a hammer
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the operator’s compartment.
5) Only qualified workers must carry out work and operation which require license or qualification.
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
8) Before starting work, warm up your body thoroughly to start work under good condition.
9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition.
S.S 28/12/24
