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Komatsu D375A-6R Crawler Bulldozer Shop Manual SEN05214-03 – PDF DOWNLOAD
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Komatsu D375A-6R Crawler Bulldozer Shop Manual
SERIAL NUMBERS 65001 and up
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Description
Komatsu D375A-6R Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D375A-6R Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D375A-6R
Serial Number: 65001 and up
Book Code: SEN05214-03
Language: English
Pages: 1766
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D375A-6R Crawler Bulldozer Shop Manual
How to read the shop manual:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword, safety and basic information. If any revision is made, the LIST OF REVISED PAGES will be added.
01. Specification:
This section explains the specifications of the machine.
10. Structure and function:
This section explains the structure and function of each component. It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table:
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting:
This section explains measuring tools and measuring methods for testing and adjusting, as well as the adjusting method of each part. The standard values and judgment criteria for “Testing and adjusting” are
explained in “Standard value table”.
40. Troubleshooting:
This section explains how to find out failed parts and how to repair them. The troubleshooting is dividedby failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard:
This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
80. Appendix:
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections.
90. Diagrams and drawings (chassis volume) /Repair and replacement of parts (engine volume):
- Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams. - Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.
TABLE OF CONTENTS:
Komatsu D375A-6R Crawler Bulldozer Shop Manual
COVER ................................................................................................................................................................................................ 1 Notice of revision.................................................................................................................................................................................... 3 00 Index and foreword................................................................................................................................................................................. 12 Table of contents................................................................................................................................................................................. 13 Table of contents............................................................................................................................................................................. 13 Forword and general information................................................................................................................................................................... 26 Safety notice................................................................................................................................................................................. 27 How to read the shop manual................................................................................................................................................................... 31 Explanation of terms for maintenance standard................................................................................................................................................. 33 Handling of electric equipment and hydraulic components....................................................................................................................................... 35 Handling of connectors newly used for engines................................................................................................................................................. 44 How to read electric wire code................................................................................................................................................................ 47 Precautions when carrying out work............................................................................................................................................................ 50 Method of disassembling and connecting push-pull type coupler................................................................................................................................. 53 Standard tightening torque table.............................................................................................................................................................. 56 List of Abbreviation.......................................................................................................................................................................... 60 Conversion table.............................................................................................................................................................................. 64 01 Specification...................................................................................................................................................................................... 70 Specification and technical data.................................................................................................................................................................. 72 Specification drawing......................................................................................................................................................................... 72 Specifications................................................................................................................................................................................ 73 Weight table.................................................................................................................................................................................. 78 Table of fuel, coolant and lubricants......................................................................................................................................................... 80 10 Structure and function............................................................................................................................................................................. 82 Engine and cooling system......................................................................................................................................................................... 85 Cooling system................................................................................................................................................................................ 85 Cooling fan pump.............................................................................................................................................................................. 88 Cooling fan motor............................................................................................................................................................................. 109 Power train....................................................................................................................................................................................... 115 Power train................................................................................................................................................................................... 115 Overall drawing of power train unit........................................................................................................................................................... 117 Power train hydraulic equipment arrangement drawing........................................................................................................................................... 119 Damper and universal joint.................................................................................................................................................................... 121 Torque converter and PTO...................................................................................................................................................................... 123 Torque converter control valve................................................................................................................................................................ 129 Main relief valve and torque converter relief valve........................................................................................................................................... 131 Lockup clutch ECMV and stator clutch ECMV..................................................................................................................................................... 133 Scavenging pump............................................................................................................................................................................... 138 Transmission control.......................................................................................................................................................................... 139 PCCS lever.................................................................................................................................................................................... 141 Transmission.................................................................................................................................................................................. 145 Transmission ECMV............................................................................................................................................................................. 159 Transmission lubrication relief valve......................................................................................................................................................... 164 Steering and brake control.................................................................................................................................................................... 165 Transfer unit, bevel gear shaft and steering.................................................................................................................................................. 167 Steering control valve........................................................................................................................................................................ 173 Steering clutch ECMV and Steering brake ECMV.................................................................................................................................................. 175 Parking brake valve........................................................................................................................................................................... 183 Sudden stop prevention valve.................................................................................................................................................................. 184 Final drive................................................................................................................................................................................... 186 Undercarriage and frame........................................................................................................................................................................... 191 Track frame................................................................................................................................................................................... 191 Idler cushion................................................................................................................................................................................. 193 Track roller bogie............................................................................................................................................................................ 194 Main frame.................................................................................................................................................................................... 195 Suspension.................................................................................................................................................................................... 197 Hydraulic system.................................................................................................................................................................................. 200 Work equipment hydraulic piping diagram....................................................................................................................................................... 200 PPC control piping diagram.................................................................................................................................................................... 204 Work equipment control........................................................................................................................................................................ 205 Hydraulic tank................................................................................................................................................................................ 207 Accumulator................................................................................................................................................................................... 209 PPC lock valve................................................................................................................................................................................ 210 PPC valve..................................................................................................................................................................................... 211 Piston valve.................................................................................................................................................................................. 223 Quick drop valve.............................................................................................................................................................................. 224 Pin puller switch............................................................................................................................................................................. 226 Pin puller solenoid valve..................................................................................................................................................................... 227 Blade control lever (only for the machine with dual tilt specification)....................................................................................................................... 229 Work equipment pump........................................................................................................................................................................... 231 Control valve................................................................................................................................................................................. 243 Self-pressure reducing valve.................................................................................................................................................................. 268 Work equipment.................................................................................................................................................................................... 275 Cylinder stay................................................................................................................................................................................. 275 Cab............................................................................................................................................................................................... 276 Cab mount..................................................................................................................................................................................... 276 Cab........................................................................................................................................................................................... 277 Electrical system................................................................................................................................................................................. 279 Engine control................................................................................................................................................................................ 279 Engine control system......................................................................................................................................................................... 280 CRI engine control system..................................................................................................................................................................... 289 Monitor system................................................................................................................................................................................ 291 Machine monitor............................................................................................................................................................................... 293 Lamp system................................................................................................................................................................................... 311 Engine preheat (electrical intake air heater) control......................................................................................................................................... 312 Palm command control system................................................................................................................................................................... 313 Sensor........................................................................................................................................................................................ 316 Vehicle health monitoring system (VHMS)....................................................................................................................................................... 322 ORBCOMM system................................................................................................................................................................................ 328 20 Standard value table............................................................................................................................................................................... 332 Standard service value table...................................................................................................................................................................... 334 Standard value table for engine............................................................................................................................................................... 334 Standard value table for machine.............................................................................................................................................................. 335 30 Testing and adjusting.............................................................................................................................................................................. 344 Tools for testing, adjusting and troubleshooting.................................................................................................................................................. 347 Diagnosis equipment list...................................................................................................................................................................... 347 Engine and cooling system......................................................................................................................................................................... 349 Testing engine speed.......................................................................................................................................................................... 349 Testing intake air pressure (boost pressure).................................................................................................................................................. 352 Testing exhaust temperature................................................................................................................................................................... 354 Testing exhaust gas color..................................................................................................................................................................... 357 Adjusting valve clearance..................................................................................................................................................................... 359 Measuring compression pressure................................................................................................................................................................ 361 Testing blow-by pressure...................................................................................................................................................................... 364 Testing engine oil pressure................................................................................................................................................................... 366 Handling of fuel system devices............................................................................................................................................................... 367 Releasing residual pressure from fuel system.................................................................................................................................................. 368 Testing fuel pressure......................................................................................................................................................................... 369 Handling of reduced cylinder mode operation................................................................................................................................................... 370 Handling of no injection cranking operation................................................................................................................................................... 371 Testing leakage from pressure limiter and return rate from injector........................................................................................................................... 372 Bleeding air from fuel circuit................................................................................................................................................................ 375 Testing fuel circuit for leakage.............................................................................................................................................................. 377 Replacing and adjusting alternator and air conditioner compressor belt30...................................................................................................................... 378 Measuring fan speed........................................................................................................................................................................... 379 Testing fan circuit oil pressure.............................................................................................................................................................. 380 Bleeding air from fan pump.................................................................................................................................................................... 381 Adjusting fuel control dial and decelerator pedal............................................................................................................................................. 382 Power train....................................................................................................................................................................................... 385 Testing power train oil pressure.............................................................................................................................................................. 385 Adjusting transmission output speed sensor.................................................................................................................................................... 399 Simple test procedure for brake performance................................................................................................................................................... 400 Adjusting brake pedal and parking brake lever................................................................................................................................................. 401 Adjusting position of pccs lever console...................................................................................................................................................... 404 Emergency escape method when there is failure in power train.................................................................................................................................. 405 Undercarriage and frame........................................................................................................................................................................... 407 Inspecting wear of sprocket................................................................................................................................................................... 407 Testing and adjusting track shoe tension...................................................................................................................................................... 408 Hydraulic system.................................................................................................................................................................................. 409 Testing and adjusting work equipment oil pressure............................................................................................................................................. 409 Testing control circuit main pressure......................................................................................................................................................... 412 Testing PPC valve output pressure............................................................................................................................................................. 413 Adjusting play of PPC valve................................................................................................................................................................... 415 Testing output pressure of ripper pin-puller solenoid valve................................................................................................................................... 416 Checking location of cause of hydraulic drift of blade and ripper............................................................................................................................. 417 Testing leakage inside work equipment cylinder................................................................................................................................................ 418 Releasing remaining pressure in work equipment cylinders...................................................................................................................................... 419 Bleeding air from work equipment cylinders.................................................................................................................................................... 420 Adjusting ripper lever position............................................................................................................................................................... 421 Work equipment.................................................................................................................................................................................... 423 Adjusting work equipment lock lever........................................................................................................................................................... 423 Adjusting blade............................................................................................................................................................................... 424 Cab and its attachments........................................................................................................................................................................... 427 Testing and adjusting operator's cab.......................................................................................................................................................... 427 Electrical system................................................................................................................................................................................. 433 Special functions of machine monitor (EMMS)................................................................................................................................................... 433 Handling of voltage circuit of engine controller.............................................................................................................................................. 491 Adjustment method when controller has been replaced........................................................................................................................................... 492 Preparation work for troubleshooting for electrical equipment system.......................................................................................................................... 496 Inspection procedure of diode................................................................................................................................................................. 500 Handling of optional devices.................................................................................................................................................................. 501 Request for opening ORBCOMM terminal.......................................................................................................................................................... 502 Initialization procedures for VHMS controller................................................................................................................................................. 504 Using method of KOMTRAX functions of ORBCOMM terminal......................................................................................................................................... 518 Precautions for replacing VHMS controller..................................................................................................................................................... 521 Pm Clinic......................................................................................................................................................................................... 527 Pm Clinic service............................................................................................................................................................................. 527 40 Troubleshooting.................................................................................................................................................................................... 538 General information on troubleshooting............................................................................................................................................................ 547 Points to remember when troubleshooting....................................................................................................................................................... 547 Sequence of events in troubleshooting......................................................................................................................................................... 548 Checks before troubleshooting................................................................................................................................................................. 549 Classification and procedures for troubleshooting............................................................................................................................................. 574 Failure codes table........................................................................................................................................................................... 577 Classification and procedures for troubleshooting numbers..................................................................................................................................... 587 Information in troubleshooting table.......................................................................................................................................................... 589 Troubleshooting method for disconnecting wiring harness of pressure sensor system............................................................................................................. 591 Connection table for connector pin numbers.................................................................................................................................................... 594 T-branch box and T-branch adapter table....................................................................................................................................................... 630 Connector list and layout..................................................................................................................................................................... 633 Fuse locations table.......................................................................................................................................................................... 647 Troubleshooting by failurecode.................................................................................................................................................................... 651 Failure code [1380MW] Lock up clutch: Slip.................................................................................................................................................... 651 Failure code [1500L0] Transmission clutch: Abnormal........................................................................................................................................... 652 Failure code [15E0MW] Transmission clutch: Slip............................................................................................................................................... 653 Failure code [15SAL1] Forward clutch: Fill high............................................................................................................................................... 655 Failure code [15SALH] Forward clutch: Fill Low................................................................................................................................................ 657 Failure code [15SBL1] Reverse clutch: Fill high............................................................................................................................................... 659 Failure code [15SBLH] Reverse clutch: Fill Low................................................................................................................................................ 661 Failure code [15SEL1] Speed 1st clutch: Fill high............................................................................................................................................. 663 Failure code [15SELH] Speed 1st clutch: Fill Low.............................................................................................................................................. 665 Failure code [15SFL1] Speed 2nd clutch: Fill high............................................................................................................................................. 667 Failure code [15SFLH] Speed 2nd clutch: Fill Low.............................................................................................................................................. 669 Failure code [15SGL1] Speed 3rd clutch: Fill high............................................................................................................................................. 671 Failure code [15SGLH] Speed 3rd clutch: Fill Low.............................................................................................................................................. 673 Failure code [15SJL1] L/U: Fill high.......................................................................................................................................................... 675 Failure code [15SJLH] L/U: Fill low........................................................................................................................................................... 677 Failure code [1800MW] P/T clutch: Slip........................................................................................................................................................ 679 Failure code [2201L1] Right clutch: Fill high................................................................................................................................................. 681 Failure code [2201LH] Right clutch: Fill low.................................................................................................................................................. 683 Failure code [2202L1] Left clutch: Fill high.................................................................................................................................................. 685 Failure code [2202LH] Left clutch: Fill low................................................................................................................................................... 687 Failure code [2300NR] Brake Themal Load Abnormality........................................................................................................................................... 689 Failure code [2301L1] Right brake: Fill high.................................................................................................................................................. 691 Failure code [2301LH] Right brake: Fill low................................................................................................................................................... 693 Failure code [2301NR] Steering Brake RH Themal Load Abnormality............................................................................................................................... 695 Failure code [2302L1] Left brake: Fill high................................................................................................................................................... 697 Failure code [2302LH] Left brake: Fill low.................................................................................................................................................... 699 Failure code [2302NR] Steering Brake LH Themal Load Abnormality............................................................................................................................... 701 Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection........................................................................................................................................ 703 Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit........................................................................................................................................ 705 Failure code [AA10NX] Air Cleaner Clogging.................................................................................................................................................... 707 Failure code [AB00MA] Battery Charge Abnormal................................................................................................................................................. 709 Failure code [B@BAZG] Eng Oil Press Low....................................................................................................................................................... 710 Failure code [B@BAZK] Eng Oil Level Low....................................................................................................................................................... 711 Failure code [B@BCNS] Eng Water Overheat...................................................................................................................................................... 712 Failure code [B@BCZK] Eng Water Level Low..................................................................................................................................................... 713 Failure code [B@CENS] T/C Oil Overheat........................................................................................................................................................ 714 Failure code [B@HANS] Hyd Oil Overheat........................................................................................................................................................ 715 Failure code [B@HAZK] Hyd Oil Level Low....................................................................................................................................................... 716 Failure code [CA111] ECM Critical Internal Failure............................................................................................................................................ 717 Failure code [CA115] Eng Ne and Bkup Speed Sens Error......................................................................................................................................... 719 Failure code [CA122] Chg Air Press Sensor High Error.......................................................................................................................................... 721 Failure code [CA123] Chg Air Press Sensor Low Error........................................................................................................................................... 723 Failure code [CA131] Throttle Sensor High Error............................................................................................................................................... 725 Failure code [CA132] Throttle Sensor Low Error................................................................................................................................................ 727 Failure code [CA135] Eng Oil Press Sensor High Error.......................................................................................................................................... 729 Failure code [CA141] Eng Oil Press Sensor Low Error........................................................................................................................................... 731 Failure code [CA144] Coolant Temp Sens High Error............................................................................................................................................. 733 Failure code [CA145] Coolant Temp Sens Low Error.............................................................................................................................................. 735 Failure code [CA153] Chg Air Temp Sensor High Error........................................................................................................................................... 737 Failure code [CA154] Chg Air Temp Sensor Low Error............................................................................................................................................ 739 Failure code [CA187] Sens Supply 2 Volt Low Error............................................................................................................................................. 741 Failure code [CA212] Eng Oil Temp Sensor High Error........................................................................................................................................... 743 Failure code [CA213] Eng Oil Temp Sensor Low Error............................................................................................................................................ 745 Failure code [CA221] Ambient Press Sens High Error............................................................................................................................................ 747 Failure code [CA222] Ambient Press Sens Low Error............................................................................................................................................. 749 Failure code [CA227] Sens Supply 2 Volt High Error............................................................................................................................................ 751 Failure code [CA234] Eng Overspeed............................................................................................................................................................ 752 Failure code [CA238] Ne Speed Sens Supply Volt Error.......................................................................................................................................... 753 Failure code [CA263] Fuel Temp Sensor High Error.............................................................................................................................................. 755 Failure code [CA265] Fuel Temp Sensor Low Error............................................................................................................................................... 757 Failure code [CA271] IMV/PCV1 Short Error..................................................................................................................................................... 759 Failure code [CA272] IMV/PCV1 Open Error...................................................................................................................................................... 760 Failure code [CA273] PCV2 Short Error......................................................................................................................................................... 761 Failure code [CA274] PCV2 Open Error.......................................................................................................................................................... 762 Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................................................................................................ 763 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................................................................................................ 765 Failure code [CA324] Inj #3 (L#3) Open/Short Error............................................................................................................................................ 767 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................................................................................................ 769 Failure code [CA331] Inj #2 (L#2) Open/Short Error............................................................................................................................................ 771 Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................................................................................................................ 773 Failure code [CA342] Calibration Code Incompatibility......................................................................................................................................... 775 Failure code [CA351] Injectors Drive Circuit Error............................................................................................................................................ 776 Failure code [CA352] Sens Supply 1 Volt Low Error............................................................................................................................................. 777 Failure code [CA386] Sens Supply 1 Volt High Error............................................................................................................................................ 779 Failure code [CA441] Battery Voltage Low Error................................................................................................................................................ 780 Failure code [CA442] Battery Voltage High Error............................................................................................................................................... 781 Failure code [CA449] Rail Press Very High Error............................................................................................................................................... 782 Failure code [CA451] Rail Press Sensor High Error............................................................................................................................................. 783 Failure code [CA452] Rail Press Sensor Low Error.............................................................................................................................................. 785 Failure code [CA553] Rail Press High Error.................................................................................................................................................... 787 Failure code [CA554] Rail Press Sensor In Range Error......................................................................................................................................... 788 Failure code [CA559] Rail Press Low Error..................................................................................................................................................... 789 Failure code [CA689] Eng Ne Speed Sensor Error................................................................................................................................................ 793 Failure code [CA731] Eng Bkup Speed Sens Phase Error.......................................................................................................................................... 795 Failure code [CA757] All Continuous Data Lost Error........................................................................................................................................... 796 Failure code [CA778] Eng Bkup Speed Sensor Error.............................................................................................................................................. 797 Failure code [CA1633] KOMNET Datalink Timeout Error........................................................................................................................................... 799 Failure code [CA2185] Throt Sens Sup Volt High Error.......................................................................................................................................... 800 Failure code [CA2186] Throt Sens Sup Volt Low Error........................................................................................................................................... 801 Failure code [CA2249] Rail Press Very Low Error............................................................................................................................................... 802 Failure code [D110KB] Battery Relay: Drive Short Circuit...................................................................................................................................... 803 Failure code [D130KA] Neutral relay: Disconnection............................................................................................................................................ 805 Failure code [D130KB] Neutral relay: Short circuit............................................................................................................................................ 807 Failure code [D161KA] Back-up alarm releay: Disconnection..................................................................................................................................... 809 Failure code [D161KB] Back-up alarm releay: Short circuit..................................................................................................................................... 811 Failure code [D182KZ] Preheater Relay Abnormality............................................................................................................................................. 813 Failure code [D190KA] ACC signal relay: Disconnection......................................................................................................................................... 815 Failure code [D190KB] ACC signal relay: Short circuit......................................................................................................................................... 817 Failure code [D1EFKA] Pre lub. motor relay: Disconnection..................................................................................................................................... 819 Failure code [D1EFKB] Pre lub. motor relay: Short circuit..................................................................................................................................... 821 Failure code [DAFRKR] Monitor: Can communication lost (PT).................................................................................................................................... 823 Failure code [dAFRKR] Monitor: CAN communication lost (WE).................................................................................................................................... 824 Failure code [DAFRMC] CAN Discon (Monitor Detected)........................................................................................................................................... 825 Failure code [DB2RKR] ENG cont.: Can communication lost (PT).................................................................................................................................. 831 Failure code [dB2RKR] ENG controller: CAN communication lost (WE)............................................................................................................................. 835 Failure code [DB90KT] WE controller: Abnormality in controller................................................................................................................................ 836 Failure code [DB91KK] WE controller: Source voltage reduction................................................................................................................................. 837 Failure code [DB92KK] WE controller: Output voltage reduction................................................................................................................................. 839 Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction.............................................................................................................................. 841 Failure code [DB99KQ] WE controller: Type select signal....................................................................................................................................... 843 Failure code [DB9RKR] WE controller: Can communication lost (PT).............................................................................................................................. 844 Failure code [DBB0KK] VHMS controller:Source voltage reduction................................................................................................................................ 847 Failure code [DBB0KQ] VHMS connector connection abnormality................................................................................................................................... 849 Failure code [DBB3KK] VHMS controller: Source voltage reduction............................................................................................................................... 850 Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction.................................................................................................................................. 853 Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction................................................................................................................................... 855 Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction................................................................................................................................... 857 Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)................................................................................................................................. 859 Failure code [DBE0KT] PT controller: Abnormality in controller................................................................................................................................ 860 Failure code [DBE1KK] PT controller: Source voltage reduction................................................................................................................................. 861 Failure code [DBE2KK] PT controller: Output voltage reduction................................................................................................................................. 863 Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction.............................................................................................................................. 865 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction.................................................................................................................................. 867 Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction.................................................................................................................................. 869 Failure code [DBE9KQ] PT controller: Type select signal....................................................................................................................................... 871 Failure code [DBERKR] PT controller: Can communication lost (WE).............................................................................................................................. 872 Failure code [DD12KA] Shift up Sw: Disconnection.............................................................................................................................................. 875 Failure code [DD12KB] Shift up Sw: Short circuit.............................................................................................................................................. 877 Failure code [DD13KA] Shift down Sw: Disconnection............................................................................................................................................ 879 Failure code [DD13KB] Shift down Sw: Short circuit............................................................................................................................................ 881 Failure code [DD14KA] Parking lever Sw: Dissconnection........................................................................................................................................ 883 Failure code [DD14KB] Parking lever Sw: Short circuit......................................................................................................................................... 885 Failure code [DDB9L4] Reverse SW Signal disagreement.......................................................................................................................................... 887 Failure code [DDE2KA] Pre lub. oil press sw: Disconnection.................................................................................................................................... 889 Failure code [DDK3L4] Forward SW Signal disagreement.......................................................................................................................................... 891 Failure code [DDK5KA] Shift switch disconnection.............................................................................................................................................. 893 Failure code [DDK5KB] Shift switch short circuit.............................................................................................................................................. 895 Failure code [DDN2LD] Blade tilt RH pressure SW abnormality................................................................................................................................... 897 Failure code [DDN3LD] Blade tilt LH pressure SW abnormality................................................................................................................................... 899 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection....................................................................................................................................... 901 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit....................................................................................................................................... 903 Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection......................................................................................................................................... 905 Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit......................................................................................................................................... 907 Failure code [DDNALD] Blade lift up pressure SW abnormality................................................................................................................................... 909 Failure code [DDNCLD] Ripper lift down pressure SW abnormality................................................................................................................................ 913 Failure code [DDNDLD] Ripper tilt in pressure SW abnormality.................................................................................................................................. 915 Failure code [DDNELD] Ripper tilt back pressure SW abnormality................................................................................................................................ 917 Failure code [DDNFLD] Blade lift down pressure SW abnormality................................................................................................................................. 919 Failure code [DDNLKA] Weq lock Sw: Disconnection.............................................................................................................................................. 921 Failure code [DDNLKB] Weq lock Sw: Short circuit.............................................................................................................................................. 923 Failure code [DDT5KA] Neutral switch disconnection............................................................................................................................................ 925 Failure code [DDT5KB] Neutral switch short circuit............................................................................................................................................ 927 Failure code [DDT5KQ] Lever SPEC selection signal disagreement................................................................................................................................ 929 Failure code [DDTSL1] S/C: Fill high.......................................................................................................................................................... 931 Failure code [DDTSLH] S/C: Fill low........................................................................................................................................................... 933 Failure code [DGE5KX] Ambient temp sensor abnormality......................................................................................................................................... 935 Failure code [DGS1KX] Hyd oil temp: signal abnormal........................................................................................................................................... 937 Failure code [DGT1KA] T/C oil temp sensor: Abnormal........................................................................................................................................... 939 Failure code [DGT1KX] T/C oil temp sensor: Abnormal........................................................................................................................................... 941 Failure code [DGT5KA] F exhaust temp sensor disconnection..................................................................................................................................... 943 Failure code [DGT5KB] F exhaust temp sensor short circuit..................................................................................................................................... 945 Failure code [DGT6KA] R exhaust temp sensor disconnection..................................................................................................................................... 947 Failure code [DGT6KB] R exhaust temp sensor short circuit..................................................................................................................................... 949 Failure code [DH21KA] Weq pressure sensor: Disconnection...................................................................................................................................... 951 Failure code [DH21KB] Weq pressure sensor: Short circuit...................................................................................................................................... 953 Failure code [DHE5KB] ENG blow-by pressure sensor disconnection............................................................................................................................... 955 Failure code [DHE5KY] ENG blow-by pressure sensor short circuit............................................................................................................................... 957 Failure code [DHT3KX] T/M oil pressure sensor abnormality..................................................................................................................................... 959 Failure code [DHT5KA] T/C in-pressure sensor: Disconnection................................................................................................................................... 961 Failure code [DHT5KB] T/C in-pressure sensor: Short circuit................................................................................................................................... 963 Failure code [DHT7KA] T/C out-pressure sensor: Disconnection.................................................................................................................................. 965 Failure code [DHT7KB] T/C out-pressure sensor: Short circuit.................................................................................................................................. 967 Failure code [DK10KA] Fuel control Dial: Disconnection........................................................................................................................................ 969 Failure code [DK10KB] Fuel control Dial: Short circuit........................................................................................................................................ 971 Failure code [DK30KA] ST lever 1: Disconnection............................................................................................................................................... 973 Failure code [DK30KB] ST lever 1: Short circuit............................................................................................................................................... 975 Failure code [DK30KX] ST lever: Out of normal range........................................................................................................................................... 977 Failure code [DK30KZ] ST lever: Disconnection or short circuit................................................................................................................................ 978 Failure code [DK30L8] ST lever: Signal mismatch............................................................................................................................................... 979 Failure code [DK31KA] ST lever 2: Disconnection............................................................................................................................................... 981 Failure code [DK31KB] ST lever 2: Short circuit............................................................................................................................................... 983 Failure code [DK40KA] Brake potentiometer: Disconnection...................................................................................................................................... 985 Failure code [DK40KB] Brake potentiometer: Short circuit...................................................................................................................................... 987 Failure code [DK55KX] FR lever: Out of normal range........................................................................................................................................... 989 Failure code [DK55KZ] FR lever: Disconnection or short circuit................................................................................................................................ 990 Failure code [DK55L8] FR lever: Signal mismatch............................................................................................................................................... 991 Failure code [DK56KA] FR lever 1: Disconnection............................................................................................................................................... 993 Failure code [DK56KB] FR lever 1: Short circuit............................................................................................................................................... 995 Failure code [DK57KA] FR lever 2: Disconnection............................................................................................................................................... 997 Failure code [DK57KB] FR lever 2: Short circuit............................................................................................................................................... 999 Failure code [DK60KA] Acceleration sensor: Disconnection......................................................................................................................................1001 Failure code [DK60KB] Acceleration sensor: Short circuit......................................................................................................................................1003 Failure code [DKH1KA] Pitch angle sensor: Disconnection.......................................................................................................................................1005 Failure code [DKH1KB] Pitch angle sensor: Short circuit.......................................................................................................................................1007 Failure code [DLF1KA] T/C out-speed sensor: Disconnection.....................................................................................................................................1009 Failure code [DLM3KA] Fan rev. sensor: Disconnection..........................................................................................................................................1011 Failure code [DLM3MB] Fan control: Decline....................................................................................................................................................1013 Failure code [DLT3KA] T/M out-speed sensor: Disconnection.....................................................................................................................................1014 Failure code [DLT3KB] T/M out-speed sensor: Abnormal..........................................................................................................................................1015 Failure code [DW59KA] Blade dual selector SOL disconnection...................................................................................................................................1016 Failure code [DW59KB] Blade dual selector SOL short circuit...................................................................................................................................1017 Failure code [DW59KY] Blade dual selector SOL hot short.......................................................................................................................................1019 Failure code [DW5AKA] Blade pitch selector SOL disconnection..................................................................................................................................1021 Failure code [DW5AKB] Blade pitch selector SOL short circuit..................................................................................................................................1022 Failure code [DW5AKY] Blade pitch selector SOL Short circuit..................................................................................................................................1023 Failure code [DW7BKA] Fan rev EPC: Disconnection..............................................................................................................................................1025 Failure code [DW7BKB] Fan rev EPC: Short circuit..............................................................................................................................................1026 Failure code [DWN3KA] Ssp solenoid: Disconnection.............................................................................................................................................1027 Failure code [DWN3KB] Ssp solenoid: Short circuit.............................................................................................................................................1029 Failure code [DWN3KY] SSP solenoid: Short circuit.............................................................................................................................................1031 Failure code [DWN5KA] Fan pump solenoid 1: Disconnection......................................................................................................................................1033 Failure code [DWN5KB] Fan pump solenoid 1: Short circuit......................................................................................................................................1035 Failure code [DWN5KY] Fan pump solenoid 1: Short circuit......................................................................................................................................1037 Failure code [DWNCKA] Fan pump solenoid 2: Disconnection......................................................................................................................................1039 Failure code [DWNCKB] Fan pump solenoid 2: Short circuit......................................................................................................................................1041 Failure code [DWNCKY] Fan pump solenoid 2: Short circuit......................................................................................................................................1043 Failure code [DXH1KA] Lock-up ECMV: Disconnection.............................................................................................................................................1045 Failure code [DXH1KB] Lock-up ECMV: Short circuit.............................................................................................................................................1046 Failure code [DXH1KY] Lock-up ECMV: Short circuit.............................................................................................................................................1047 Failure code [DXH4KA] 1st clutch ECMV: Disconnection..........................................................................................................................................1049 Failure code [DXH4KB] 1st clutch ECMV: Short circuit..........................................................................................................................................1051 Failure code [DXH4KY] 1st clutch ECMV: Short circuit..........................................................................................................................................1053 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection..........................................................................................................................................1055 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit..........................................................................................................................................1057 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit..........................................................................................................................................1059 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection..........................................................................................................................................1061 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit..........................................................................................................................................1063 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit..........................................................................................................................................1065 Failure code [DXH7KA] R clutch ECMV: Disconnection............................................................................................................................................1067 Failure code [DXH7KB] R clutch ECMV: Short circuit............................................................................................................................................1069 Failure code [DXH7KY] R clutch ECMV: Short circuit............................................................................................................................................1071 Failure code [DXH8KA] F clutch ECMV: Disconnection............................................................................................................................................1073 Failure code [DXH8KB] F clutch ECMV: Short circuit............................................................................................................................................1075 Failure code [DXH8KY] F clutch ECMV: Short circuit............................................................................................................................................1077 Failure code [DXH9KA] Right clutch ECMV: Disconnection........................................................................................................................................1079 Failure code [DXH9KB] Right clutch ECMV: Short circuit........................................................................................................................................1081 Failure code [DXH9KY] Right clutch ECMV: Short circuit........................................................................................................................................1083 Failure code [DXHAKA] Left clutch ECMV: Disconnection.........................................................................................................................................1085 Failure code [DXHAKB] Left clutch ECMV: Short circuit.........................................................................................................................................1087 Failure code [DXHAKY] Left clutch ECMV: Short circuit.........................................................................................................................................1089 Failure code [DXHBKA] Right brake ECMV: Disconnection.........................................................................................................................................1091 Failure code [DXHBKB] Right brake ECMV: Short circuit.........................................................................................................................................1093 Failure code [DXHBKY] Right brake ECMV: Short circuit.........................................................................................................................................1095 Failure code [DXHCKA] Left brake ECMV: Disconnection..........................................................................................................................................1097 Failure code [DXHCKB] Left brake ECMV: Short circuit..........................................................................................................................................1099 Failure code [DXHCKY] Left brake ECMV: Short circuit..........................................................................................................................................1101 Failure code [DXJBKA] S/C ECMV: Disconnection.................................................................................................................................................1103 Failure code [DXJBKB] S/C ECMV: Short circuit.................................................................................................................................................1104 Failure code [DXJBKY] S/C ECMV: Short circuit.................................................................................................................................................1105 Failure code [DY2HKA] Pre lub. motor: Disconnection...........................................................................................................................................1107 Failure code [F@BBZL] ENG blow-by pressure high level.........................................................................................................................................1109 Failure code [F@BYNR] F exhaust temp high level (2)...........................................................................................................................................1110 Failure code [F@BYNS] F exhaust temp high level (1)...........................................................................................................................................1111 Failure code [F@BZNR] R exhaust temp high level (2)...........................................................................................................................................1112 Failure code [F@BZNS] R exhaust temp high level (1)...........................................................................................................................................1113 Troubleshooting of electrical system (E-mode).....................................................................................................................................................1115 Information contained in troubleshooting table................................................................................................................................................1115 E-1 Engine does not start (starting motor does not turn)......................................................................................................................................1117 E-2 Preheater does not operate................................................................................................................................................................1121 E-3 When starting switch is turned ON, machine monitor displays nothing.......................................................................................................................1125 E-4 When starting switch is turned ON (before starting engine), basic check item lights up....................................................................................................1129 E-5 Precaution item lights up while engine is running.........................................................................................................................................1131 E-6 Emergency stop item lights up while engine is running.....................................................................................................................................1133 E-7 Engine coolant temperature gauge does not indicate normally...............................................................................................................................1134 E-8 Fuel gauge does not indicate properly.....................................................................................................................................................1135 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally................................................................................................................1137 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally.....................................................................................................................1138 E-11 Contents of display by machine monitor are different from applicable machine.............................................................................................................1139 E-12 Machine monitor does not display some items..............................................................................................................................................1139 E-13 Function switch does not work............................................................................................................................................................1139 E-14 Operation mode does not change...........................................................................................................................................................1140 E-15 Gearshift mode does not change...........................................................................................................................................................1140 E-16 Customize function does not operate normally.............................................................................................................................................1141 E-17 Customize memory function does not operate normally......................................................................................................................................1141 E-18 Alarm buzzer does not sound or does not stop.............................................................................................................................................1142 E-19 When starting switch is turned OFF, service meter is not displayed40.....................................................................................................................1142 E-20 Machine monitor cannot be set in service mode............................................................................................................................................1142 E-21 The ripper pin puller cylinder does not operate..........................................................................................................................................1143 E-22 Horn does not sound or does not stop.....................................................................................................................................................1145 E-23 Back-up alarm does not sound or does not stop............................................................................................................................................1147 E-24 Fan does not reverse.....................................................................................................................................................................1149 E-25 The head lamp and rear lamp do not light up..............................................................................................................................................1150 E-26 Windshield wiper does not operate........................................................................................................................................................1159 E-27 Window washer does not operate...........................................................................................................................................................1167 E-28 Electric priming pump does not operate or does not stop automati cally...................................................................................................................1175 E-29 Orbcomm terminal does not operate normally (Data are not transmitted)....................................................................................................................1177 E-30 Gear cannot be shifted...................................................................................................................................................................1179 Troubleshooting of hydraulic and mechanical system (H-mode).......................................................................................................................................1181 Information in troubleshooting table..........................................................................................................................................................1181 List of Failure Modes and Causes..............................................................................................................................................................1183 H-1 Machine lacks power(or drawbar pull)......................................................................................................................................................1185 H-2 Machine cannot travel (at 2nd or 3rd each speed)..........................................................................................................................................1187 H-3 Machine cannot travel at any gear speeds..................................................................................................................................................1188 H-4 Machine travels only in one direction, forward or reverse.................................................................................................................................1190 H-5 Large time lag at gear shifting or directional change.....................................................................................................................................1191 H-6 Machine connot turn.......................................................................................................................................................................1192 H-7 Machine turns only to one side............................................................................................................................................................1193 H-8 Machine overruns at turnning..............................................................................................................................................................1194 H-9 Brake does not work.......................................................................................................................................................................1195 H-10 Torque converter does not lock up........................................................................................................................................................1196 H-11 Power train oil overheats................................................................................................................................................................1197 H-12 All work equipment operates too slow or lacks power......................................................................................................................................1198 H-13 All work equipment does not operate......................................................................................................................................................1199 H-14 Blade lift cylinder speed is too slow or lacks power.....................................................................................................................................1200 H-15 Blade tilt cylinder speed is too slow or lacks power.....................................................................................................................................1201 H-16 Ripper lift cylinder speed is too slow or lacks power....................................................................................................................................1202 H-17 Ripper tilt cylinder speed is too slow or lacks power....................................................................................................................................1203 H-18 Excessive hydraulic drift of blade lift cylinder.........................................................................................................................................1204 H-19 Excessive hydraulic drift of blade tilt cylinder.........................................................................................................................................1205 H-20 Excessive hydraulic drift of ripper lift cylinder........................................................................................................................................1206 H-21 Ripper pin puller cylinder does not operate (machine with giant ripper)..................................................................................................................1207 H-22 Blade pitch does not work (machine with dual tilt specification).........................................................................................................................1208 H-23 Abnormal noise from around work equipment pump...........................................................................................................................................1209 H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)...................................................................................................1210 Troubleshooting of engine (S-mode)................................................................................................................................................................1211 Method of using troubleshooting chart.........................................................................................................................................................1211 S-1 Engine does not start easily..............................................................................................................................................................1215 S-2 Engine does not start.....................................................................................................................................................................1216 S-3 Engine does not rev up smoothly (response-up is poor).....................................................................................................................................1219 S-4 Engine stops during operation.............................................................................................................................................................1220 S-5 Engine does not rotate smoothly (hunting).................................................................................................................................................1221 S-6 Engine lacks power (or output shortage)...................................................................................................................................................1222 S-7 Exhaust smoke is black (Incomplete combustion)............................................................................................................................................1223 S-8 Oil is consumption is excessive(or exhaust smoke is blue).................................................................................................................................1224 S-9 Engine oil becomes contaminated quickly...................................................................................................................................................1225 S-10 Fuel consumption is excessive............................................................................................................................................................1226 S-11 Oil mixes into coolant(coolant blows back or is reduced).................................................................................................................................1227 S-12 Engine pressure monitor lights up (drop in engine oil pressure)..........................................................................................................................1228 S-13 Oil level rises (Coolant or fuel mixes into oil).........................................................................................................................................1229 S-14 Coolant temperature rises too high (overheating).........................................................................................................................................1230 S-15 Abnormal noise is heard..................................................................................................................................................................1231 S-16 Vibration is excessive...................................................................................................................................................................1232 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)....1233 50 Disassembly and assembly...........................................................................................................................................................................1236 General information on disassembly and assembly...................................................................................................................................................1239 How to read this manual.......................................................................................................................................................................1239 Coating materials list........................................................................................................................................................................1241 Special tool list.............................................................................................................................................................................1244 Sketches of special tools.....................................................................................................................................................................1252 Engine and cooling system.........................................................................................................................................................................1260 Removal and installation of fuel supply pump assembly.........................................................................................................................................1260 Removal and installation of fuel injector assembly............................................................................................................................................1265 Removal and installation of cylinder head assembly............................................................................................................................................1270 Removal and installation of radiator guard assembly...........................................................................................................................................1285 Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)...............................................................................................1290 Removal and installation of radiator..........................................................................................................................................................1295 Removal and installation of hydraulic oil cooler..............................................................................................................................................1297 Removal and installation of aftercooler.......................................................................................................................................................1298 Removal and installation of engine assembly...................................................................................................................................................1299 Removal and installation of engine hood assembly..............................................................................................................................................1306 Removal and installation of engine front seal.................................................................................................................................................1309 Removal and installation of engine rear seal..................................................................................................................................................1311 Removal and installation of fan drive assembly................................................................................................................................................1315 Removal and installation of fan motor assembly................................................................................................................................................1317 Removal and installation of fuel tank assembly................................................................................................................................................1319 Power train.......................................................................................................................................................................................1321 Removal and installation of damper assembly...................................................................................................................................................1321 Disassembly and assembly of damper assembly...................................................................................................................................................1325 Removal and installation of power train unit assembly.........................................................................................................................................1328 Disconnection and connection of power train unit assembly.....................................................................................................................................1334 Disassembly and assembly of PTO assembly......................................................................................................................................................1343 Disassembly and assembly of torque converter assembly.........................................................................................................................................1349 Disassembly and assembly of TORQFLOW transmission assembly....................................................................................................................................1358 Disassembly and assembly of steering case assembly............................................................................................................................................1385 Removal and installation of power train pump and lubrication pump assembly....................................................................................................................1401 Removal and installation of scavenging pump assembly..........................................................................................................................................1402 Removal and installation of final drive assembly..............................................................................................................................................1403 Disassembly and assembly of final drive assembly..............................................................................................................................................1405 Undercarriage and frame...........................................................................................................................................................................1418 Removal and installation of track frame assembly..............................................................................................................................................1418 Removal and installation of idler assembly....................................................................................................................................................1423 Disassembly and assembly of idler assembly....................................................................................................................................................1424 Removal and installation of recoil spring assembly............................................................................................................................................1428 Disassembly and assembly of recoil spring assembly............................................................................................................................................1433 Removal and installation of track roller assembly.............................................................................................................................................1435 Disassembly and assembly of track roller assembly.............................................................................................................................................1438 Removal and installation of carrier roller assembly...........................................................................................................................................1441 Disassembly and assembly of carrier roller assembly...........................................................................................................................................1442 Removal and installation of bogie assembly....................................................................................................................................................1446 Disassembly and assembly of bogie assembly....................................................................................................................................................1451 Removal and installation of first bogie assembly..............................................................................................................................................1453 Separation and connection of track shoe assembly..............................................................................................................................................1458 Overall disassembly and assembly of track shoe................................................................................................................................................1462 Link press press-fitting jig dimensions.......................................................................................................................................................1479 Disassembly and assembly of one link assembly in the field....................................................................................................................................1480 Disassembly and assembly of master link.......................................................................................................................................................1485 Removal and installation of pivot shaft assembly..............................................................................................................................................1489 Removal and installation of equalizer bar.....................................................................................................................................................1490 Disassembly and assembly of equalizer bar bushing.............................................................................................................................................1494 Removal and installation of segment tooth.....................................................................................................................................................1496 Hydraulic system..................................................................................................................................................................................1497 Removal and installation of hydraulic tank assembly...........................................................................................................................................1497 Removal and installation of work equipment pump assembly......................................................................................................................................1500 Removal and installation of fan pump assembly.................................................................................................................................................1504 Removal and installation of control valve assembly............................................................................................................................................1506 Disassembly and assembly of control valve assembly............................................................................................................................................1508 Disassembly and assembly of blade PPC valve assembly..........................................................................................................................................1513 Disassembly and assembly of ripper PPC valve assembly.........................................................................................................................................1516 Disassembly and assembly of hydraulic cylinder assembly.......................................................................................................................................1518 Disassembly and assembly of ripper pin puller cylinder assembly...............................................................................................................................1526 Work equipment....................................................................................................................................................................................1529 Removal and installation of blade assembly....................................................................................................................................................1529 Disassembly and assembly of blade assembly....................................................................................................................................................1531 Disassembly and assembly of giant ripper assembly.............................................................................................................................................1535 Cab and its attachments...........................................................................................................................................................................1538 Removal and installation of ROPS guard........................................................................................................................................................1538 Removal and installation of operator's cab assembly...........................................................................................................................................1539 Removal and installation of floor frame assembly..............................................................................................................................................1543 Removal and installation of air conditioner unit assembly.....................................................................................................................................1548 Electrical system.................................................................................................................................................................................1554 Removal and installation of transmission controller assembly and steering controller assembly.................................................................................................1554 Removal and installation of engine controller assembly........................................................................................................................................1555 Removal and installation of VHMS controller assembly..........................................................................................................................................1557 Removal and installation of machine monitor assembly..........................................................................................................................................1558 60 Maintenance standard...............................................................................................................................................................................1560 Engine and cooling system.........................................................................................................................................................................1562 Engine mount..................................................................................................................................................................................1562 Cooling fan pump..............................................................................................................................................................................1564 Cooling fan motor.............................................................................................................................................................................1571 Power train.......................................................................................................................................................................................1573 Power train unit..............................................................................................................................................................................1573 Damper and universal joint....................................................................................................................................................................1575 Torque converter and PTO......................................................................................................................................................................1578 Main relief valve and torque converter relief valve...........................................................................................................................................1581 Lockup clutch ECMV and stator clutch ECMV.....................................................................................................................................................1582 Scavenging pump...............................................................................................................................................................................1583 Transmission control..........................................................................................................................................................................1584 Transmission..................................................................................................................................................................................1585 Transmission lubricating oil relief valve.....................................................................................................................................................1590 Power train and lubrication pump..............................................................................................................................................................1591 Transfer, bevel gear shaft and steering unit..................................................................................................................................................1593 Steering control valve........................................................................................................................................................................1599 Steering clutch ECMV and steering brake ECMV..................................................................................................................................................1600 Parking brake valve...........................................................................................................................................................................1601 Final drive...................................................................................................................................................................................1602 Sprocket......................................................................................................................................................................................1605 Undercarriage and frame...........................................................................................................................................................................1607 Track frame...................................................................................................................................................................................1607 Idler cushion.................................................................................................................................................................................1609 Idler.........................................................................................................................................................................................1611 Track roller..................................................................................................................................................................................1613 Carrier roller................................................................................................................................................................................1615 Track roller bogie............................................................................................................................................................................1616 Track shoe....................................................................................................................................................................................1617 Main frame....................................................................................................................................................................................1621 Suspension....................................................................................................................................................................................1623 Hydraulic system..................................................................................................................................................................................1627 PPC valve.....................................................................................................................................................................................1627 Hydraulic cylinder............................................................................................................................................................................1633 Quick drop valve..............................................................................................................................................................................1636 Work equipment pump...........................................................................................................................................................................1637 Control valve.................................................................................................................................................................................1640 Self-pressure reducing valve..................................................................................................................................................................1653 Work equipment....................................................................................................................................................................................1656 Cylinder stay.................................................................................................................................................................................1656 Blade.........................................................................................................................................................................................1657 Cutting edge and end bit......................................................................................................................................................................1661 Ripper........................................................................................................................................................................................1663 80 Appendix...........................................................................................................................................................................................1666 Air conditioner...................................................................................................................................................................................1668 Precautions for refrigerant...................................................................................................................................................................1668 Air conditioner component.....................................................................................................................................................................1669 Configuration and function of refrigeration cycle.............................................................................................................................................1671 Outline of refrigeration cycle................................................................................................................................................................1672 Air conditioner unit..........................................................................................................................................................................1675 Blower unit...................................................................................................................................................................................1679 FRESH/RECIRC air changeover damper............................................................................................................................................................1680 Compressor....................................................................................................................................................................................1681 Condenser.....................................................................................................................................................................................1682 Receiver drier................................................................................................................................................................................1683 Air conditioner control panel.................................................................................................................................................................1685 Procedure for testing and troubleshooting.....................................................................................................................................................1687 Circuit diagram and arrangement of connector pins.............................................................................................................................................1689 System diagram................................................................................................................................................................................1691 Parts and connectors layout...................................................................................................................................................................1693 Testing temperature control...................................................................................................................................................................1697 Testing FRESH/RECIC air changeover............................................................................................................................................................1698 Testing relay.................................................................................................................................................................................1699 Troubleshooting chart 1.......................................................................................................................................................................1701 Troubleshooting chart 2.......................................................................................................................................................................1703 Information in troubleshooting table..........................................................................................................................................................1705 Troubleshooting for power supply system (Air conditioner does not operate)....................................................................................................................1707 Troubleshooting for compressor system (Air is not cooled).....................................................................................................................................1709 Troubleshooting for blower motor system (Air does not come out or air flow is abnormal).......................................................................................................1713 Troubleshooting for temperature control.......................................................................................................................................................1719 Troubleshooting for FRESH/RECIRC air changeover...............................................................................................................................................1721 Troubleshooting with gauge pressure...........................................................................................................................................................1723 Connection of service tool....................................................................................................................................................................1725 Precautions for disconnecting and connecting..................................................................................................................................................1727 Handling of compressor oil....................................................................................................................................................................1729 90 Diagrams and drawings..............................................................................................................................................................................1732 Hydraulic diagrams and drawings...................................................................................................................................................................1734 Symbols used in hydraulic circuit diagrams....................................................................................................................................................1734 Power train hydraulic circuit diagram.........................................................................................................................................................1736 Hydraulic circuit diagram.....................................................................................................................................................................1737 Electrical diagrams and drawings..................................................................................................................................................................1739 Symbols used in electrical circuit diagrams...................................................................................................................................................1739 Electrical circuit diagram....................................................................................................................................................................1743 Index.................................................................................................................................................................................................1757
KOMATSU D375A-6R CRAWLER BULLDOZER SHOP MANUAL SEN05214-03 – PDF DOWNLOAD:
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