Komatsu D375A-8 Bulldozer Shop Manual SEN06708-09 PDF

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Komatsu D375A-8 Bulldozer Shop Manual SEN06708-09 – PDF DOWNLOAD

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Komatsu D375A-8 Bulldozer Shop Manual SEN06708-09 – PDF DOWNLOAD 

Language : English
Pages : 3366
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D375A-8 Bulldozer Shop Manual SEN06708-09 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 24
Foreword, Safety, Basic Information 27
How to Read the Shop Manual 27
Safety Notice for Operation 29
Precautions to Prevent Fire 37
Procedures If Fire Occurs 39
Precautions When You Discard Waste Materials 40
Precautions for DEF 41
General Character and Precautions for Handling 41
Precautions for Adding 41
Precautions for Storage 41
Precautions for Fire Hazard and Leakage 41
Other Precautions 41
Store DEF 42
Precautions When You Handle Hydraulic Equipment 43
Precautions When You Disconnect and Connect Pipings 46
Precautions When You Handle Electrical Equipment 52
Precautions When You Handle Fuel System Equipment 54
Precautions When You Handle Intake System Equipment 55
Practical Use of KOMTRAX 56
Disconnect and Connect Push-Pull Type Coupler 57
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 57
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 58
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 59
Precautions for Disconnection and Connection of Connectors 61
How to Disconnect and Connect Deutsch Connector 65
How to Disconnect and Connect Slide Lock Type Connector 66
How to Disconnect and Connect Connector with Lock to Pull 68
How to Disconnect and Connect Connector with Lock to Push 69
How to Disconnect and Connect Connector with Housing to Rotate 71
How to Read the Codes for Electric Cable 72
Explanation of Terms for Maintenance Standard 76
Standard Tightening Torque Table 79
Conversion Table 86
01 Specifications 91
Table of Contents 92
Specifications 93
Specification Drawing 93
Specification Drawing: D375A-8 93
Specifications 95
Specification: D375A-8 95
Weight Table 102
Weight Table: D375A-8 102
Fuel, Coolant, Lubricants (For North America) 105
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 105
10 Structure and Function 107
Table of Contents 108
Boot-up System 111
System Operating Lamp System 111
System Diagram of System Operating Lamp System 111
Function of Operation Lamp System 111
Battery Disconnect Switch 113
Layout Drawing of Battery Disconnect Switch 113
Function of Battery Disconnect Switch 113
Battery Isolator 115
Layout Drawing of Battery Isolator 115
Function of Battery Isolator 115
Engine System 117
Layout Drawing of Engine System 117
Engine Control System 119
Layout Drawing of Engine Control System 119
System Diagram of Engine Control 120
Function of Engine Control System 121
Automatic Idle Stop System 122
System Diagram of Automatic Idle Stop System 122
Function of Automatic Idle Stop System 123
Component Parts of Engine System 126
Damper 126
VGT 128
EGR System 132
EGR Valve 135
EGR Cooler 137
KCCV System 138
KCCV Ventilator 140
KDPF 142
Fuel System 146
Fuel System Circuit Diagram 146
Function of Fuel System 147
Operation of Fuel System 147
CRI System 148
Cooling System 152
Layout Drawing of Cooling System 152
Specifications of Cooling System 153
Component Parts of Cooling System 154
Cooling Fan Pump 154
Cooling Fan Motor 174
Hydraulic Oil Cooler Bypass Valve 181
Control System 182
Layout Drawing of Control System 182
Machine Monitor System 183
System Diagram of Machine Monitor System 183
Function of Machine Monitor System 184
KOMTRAX Plus System 186
System Diagram of KOMTRAX Plus System 186
Function of KOMTRAX Plus System 186
Component Parts of Control System 188
Machine Monitor 188
KOMTRAX Terminal 205
KOMTRAX Plus Controller 207
Wireless LAN Unit 212
Power Train Controller 213
Work Equipment Controller 221
Engine Controller 225
Option Controller 238
Fuel Feed Pump 242
Fuel Feed Pump Switch 243
Hydraulic System 244
Layout Drawing of Hydraulic System 244
CLSS 245
Structure of CLSS 245
Function of CLSS 246
Component Parts of Hydraulic System 248
Hydraulic Tank 248
Work Equipment Pump 250
LS Valve 254
PTO, Transmission Lubrication Pump, and Power Train Pump 259
Control Valve 261
Power Train System 281
Layout Drawing of Power Train System 281
Operation of Power Train System 284
Transmission, Steering, and Brake Control 285
Layout Drawing of Transmission, Steering, and Brake Control System 285
Function of Transmission, Steering, and Brake Control System 286
Layout of Transmission, Steering, and Brake Control System Parts (Machine with FCCS) 287
Function of Transmission, Steering, and Brake Control System (Machine with FCCS) 289
Palm Command Control System 290
Palm Command Control System Diagram 290
Centralized Pressure Pickup Port 294
Layout Drawing of Centralized Pressure Pickup Port 294
Function of Centralized Pressure Pickup Port 295
Component Parts of Power Train System 296
Universal Joint 296
Power Train Mount 297
Torque Converter and PTO 299
Torque Converter Control Valve 306
Lockup Clutch ECMV 308
Stator Clutch ECMV 312
Transmission 316
Transmission ECMV 330
Main Relief Valve and Torque Converter Relief Valve 336
Transmission Lubrication Relief Valve 339
Transfer and Bevel Pinion 340
Bevel Gear Shaft, Steering Clutch, and Brake 341
Final Drive 349
Scavenging Pump 353
Electric Steering Electric Lever 354
Work Equipment System 360
Work Equipment Control 360
Layout Drawing of Work Equipment Control 360
Function of Work Equipment Control 361
Layout Drawing of Front Work Equipment 362
Layout Drawing of Variable Giant Ripper 363
Layout Drawing of Variable Multi-Shank Ripper 364
Shoe Slip Control System 365
Function of Shoes Slip Control System 365
Component Parts of Work Equipment System 366
Self-Pressure Reducing Valve 366
Work Equipment Lock Solenoid Valve 371
Pilot Circuit Accumulator 373
Quick Drop Valve 374
Piston Valve 376
Electric Blade Control Lever 377
Ripper Electric Lever 378
Pin Puller Switch 379
Lifting System 380
Power Ladder System 380
Layout Drawing of Power Ladder System 380
Hydraulic Circuit Diagram of Power Ladder System 381
Function of Power Ladder System 382
Component Parts of Lifting System 383
Switch Box 383
Power Ladder Limit Switch Part 384
Control Valve Assembly 385
Radio Control System 386
Layout Drawing of Radio Control System 386
Specifications of Radio Control System 387
Component Parts of Radio Control System 388
Radio Control Transmitter 388
Radio Control Receiver 390
Radio Control On-board Selector Switch 391
Undercarriage and Frame 393
Main Frame 393
Structure of Main Frame 393
Suspension 395
Structure of Suspension 395
Function of Suspension 397
Track Frame and Idler Cushion 398
Structure of Track Frame and Idler Cushion 398
Specifications of Track Frame and Idler Cushion 399
Function of Track Frame and Idler Cushion 399
Work Equipment 400
Structure of Front Work Equipment 400
Structure of Cylinder Stay 402
Structure of Variable Giant Ripper 403
Structure of Variable Multi-Shank Ripper 404
CAB Related Parts 405
ROPS 405
Structure of ROPS 405
Function of ROPS 405
CAB 406
Structure of CAB 406
CAB Mount 407
Structure of CAB Mount 407
20 Standard Value Table 409
Table of Contents 410
Standard Value Table for Engine 411
Standard Value Table for Engine: D375A-8 411
Standard Value Table for Machine 417
Standard Value Table for Machine: D375A-8 417
Machine Posture and Procedures to Measure Performance 441
30 Testing and Adjusting 445
Table of Contents 446
Precautions Before Work 449
Related Information on Testing and Adjusting 450
Tools for Testing and Adjusting 450
Sketch of Tools for Testing and Adjusting 456
Engine and Cooling System 459
Examine Engine Speed 459
How to Examine Engine Speed 459
Examine Boost Pressure 463
How to Examine Boost Pressure on Machine Monitor 463
How to Examine Boost Pressure by Testing Tool 464
Examine Exhaust Gas Temperature 466
How to Test Exhaust Gas Temperature by the Machine Monitor 466
How to Examine Exhaust Temperature by Testing Tools 467
Examine Exhaust Gas Color 470
How to Examine Exhaust Gas Color with the Handy Smoke Checker 470
How to Examine Exhaust Gas Color with Smoke Meter 471
Examine Mass Air Flow and Temperature Sensor 474
How to Examine Mass Air Flow and Temperature Sensor 474
Examine and Adjust Valve Clearance 476
How to Examine Valve Clearance 476
How to Adjust Valve Clearance 477
Examine Compression Pressure 479
How to Examine Compression Pressure 479
Examine Blowby Pressure 483
How to Examine Blowby Pressure 483
Examine Engine Oil Pressure 485
How to Examine Engine Oil Pressure on Machine Monitor 485
How to Examine Engine Oil Pressure by Testing Tool 485
Examine EGR Valve and VGT Oil Pressure 487
How to Examine EGR Valve and VGT Oil Pressure 487
Examine Fuel Pressure 488
How to Examine Fuel Pressure 488
Examine Fuel Return Rate and Leakage 490
How to Examine Fuel Return Rate and Leakage 491
Bleed Air from Fuel System 496
How to Bleed Air from Fuel System 496
Examine Fuel Circuit for Leakage 498
How to Examine Fuel System for Leakage 498
Examine Supply Pump 500
How to Examine Supply Pump 500
Handle Cylinder Cut-out Mode Operation 503
Handle No-Injection Cranking Operation 504
Clean Fuel Doser 505
How to Clean Fuel Doser 505
Write Injector Compensation Value to Engine Controller 508
How to Write Injector Compensation Value 508
Write Correction for Ash in Soot Accumulation to Engine Controller 514
How to Write Correction for Ash in Soot Accumulation to Engine Controller 514
Adjust Decelerator Pedal 515
How to Adjust Decelerator Pedal 515
Power Train 518
Examine Power Train Oil Pressure 518
How to Examine Power Train Oil Pressure 519
Adjust Transmission Output Shaft Speed Sensor 536
How to Adjust Transmission Output Shaft Speed Sensor 536
Examine Brake Performance Simply 538
How to Examine Brake Performance Simply 538
Examine and Adjust Brake Pedal 539
How to Examine Brake Pedal 539
How to Adjust Brake Pedal 540
Adjust Parking Brake Lever 543
How to Adjust Parking Brake Lever 543
Move Machine by Parking Brake Release When Machine Does Not Travel 545
How to Move Machine with Hydraulic Type Parking Brake Release System 545
How to Move Machine with Electric Type Parking Brake Release System 546
Undercarriage and Frame 549
Examine and Adjust Track Tension 549
How to Examine Track Tension 549
How to Adjust Track Tension 549
Hydraulic System 551
Release Remained Pressure in Hydraulic Circuit 551
How to Release Remained Pressure in Hydraulic System 551
Examine and Adjust Work Equipment Oil Pressure 552
How to Examine Work Equipment Oil Pressure 552
How to Adjust Work Equipment Oil Pressure 554
Examine Oil Pressure of Control Circuit 555
How to Examine Oil Pressure in Control Circuit 555
Examine Work Equipment Lock Solenoid Valve Outlet Pressure 557
How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure 557
Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 559
How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 559
Bleed Air from Work Equipment Pump 561
How to Bleed Air from Work Equipment Pump 561
Examine Cooling Fan Speed 562
How to Examine Cooling Fan Speed 562
Examine Cooling Fan Circuit Oil Pressure 563
How to Examine Cooling Fan Circuit Oil Pressure 563
Bleed Air in Cooling Fan Pump 565
How to Bleed Air in Cooling Fan Pump 565
Examine Parts Which Cause Hydraulic Drift of Work Equipment 566
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 566
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 566
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 567
Examine Oil Leakage from Work Equipment Cylinder 568
How to Examine Internal Oil Leakage of Work Equipment Cylinder 568
Bleed Air from Work Equipment Cylinders 570
How to Bleed Air from Work Equipment Cylinder 570
Operation When Work Equipment is Disabled 571
How to Operate When Work Equipment is Disabled 571
Power Ladder 573
Bleed Air from Power Ladder Cylinder 573
How to Bleed Air in Power Ladder Cylinder 573
Examine and Adjust Power Ladder Limit Switch 578
How to Examine and Adjust Power Ladder Limit Switch 578
How to Adjust Power Ladder Limit Switch 578
Work Equipment 587
Adjust Work Equipment Lock Lever 587
How to Adjust Work Equipment Lock Lever 587
Examine and Adjust Play of Blade Electric Lever 589
How to Examine Play of Blade Electric Lever 591
How to Adjust Play of Blade Electric Lever 591
How to Replace Universal Joint 592
CAB Related Parts 599
Examine and Adjust Operator Cab 599
How to Examine Operator Cab 599
How to Adjust Operator Cab 602
Adjust Play of Operator Seat 605
How to Adjust Play of Operator Seat 605
Electrical System 606
Set and Operate Machine Monitor 606
Operator Mode 610
Function to Show Technician Identification Status Screen 610
Function to Show Operator Identification Input Screen 610
Examine Function by LCD (Liquid Crystal Display) 611
Examine Function of Service Meter 611
How to Set Usage Limitation and Change Maintenance Password 611
Service Mode 614
How to Operate Service Mode 614
How to See Pre-defined Monitoring Information 616
How to Examine Self-Define Monitor Information 621
Abnormality Record Menu 633
How to See Maintenance Record 637
Maintenance Mode Setting 638
How to Set Phone Number Entry 641
Default Menu 643
Diagnostic Tests Menu 652
Adjustment Menu 662
No-Injection Cranking Operation 732
KOMTRAX Settings Menu 734
How to Show Service Message 736
How to Operate Snap Shot 737
How to Start Up KOMTRAX Terminal 739
Default Setting of KOMTRAX Plus Controller 744
How to do the Default Setting of KOMTRAX Plus Controller 744
Default Setting of Wireless LAN Modem 747
Default Setting of Wireless LAN Modem 747
How to Examine Wireless LAN Modem Communication 748
Download Data from KOMTRAX Plus Controller 749
How to Download Data from KOMTRAX Plus Controller 749
Adjust After Replacement of KOMTRAX Plus Controller 752
How to Adjust After Replacement of KOMTRAX Plus Controller 752
Adjust After Replacement of Wireless LAN Modem 755
How to Adjust After Replacement of Wireless LAN Modem 755
Adjust Rearview Camera Angle 758
How to Adjust Rearview Camera Angle 758
Handle Voltage Circuit of Engine Controller 759
Handle Battery Disconnect Switch 760
Handle Battery Isolator and Starting Motor Isolator 761
Examine Diodes 762
How to Examine Diodes by Digital Tester 762
How to Examine Diodes by Analog Tester 762
Radio Control 763
ID Setup 763
How to Set Radio Control Transmitter ID 763
How to Set Radio Control Receiver ID 764
Pm Clinic 767
Pm Clinic Service 767
Pm Clinic Check Sheet: D375A-8 768
Pm Clinic Check Sheet for Undercarriage: D375A-8 787
Perform Quick Pm 791
How to Perform Quick Pm 791
40 Troubleshooting 795
Table of Contents 796
Precautions Before Work 809
Related Information to Troubleshooting 810
General Troubleshooting Points 810
Troubleshooting Points for Aftertreatment System 811
Sequence of Events in Troubleshooting 818
Troubleshooting for Radio Control System 820
Checks Before Troubleshooting (Specifications of Radio Control) 820
Examine Operating State of Radio Control Receiver 821
Examine Operating State of Radio Control Transmitter 822
Checks Before Troubleshooting 823
Inspection Procedure Before Troubleshooting 825
Walk-Around Check 825
Test in Accordance with Testing Procedure 827
How to Drain Water and Sediment from Fuel Tank 827
How to Examine Water Separator, Drain Water and Sediment 827
Examine Fuel Main Filter 828
How to Examine Oil Level in Hydraulic Tank, Add Oil 829
How to Examine Coolant Level, Add Coolant 831
How to Examine Oil Level in Engine Oil Pan, Add Oil 832
How to Examine Oil Level in Power Train Case, Add Oil 833
How to Examine Dust Indicator 834
How to Examine Brake Operation 835
How to Examine Electric Wiring 835
How to Examine Fuel Level, Add Fuel 835
How to Examine Operation of Lamps 836
How to Examine Machine Monitor 836
How to Remove Sediment in Engine Room 837
How to Examine Operation State of Horn 837
How to Examine Operation State of Backup Alarm 838
How to Examine Electric Equipment 838
Preparation for Troubleshooting of Electrical System 843
Preparation for Troubleshooting of Machine Monitor 843
Preparation for Troubleshooting of Engine Controller 843
Preparation for Troubleshooting of Work Equipment Controller 843
Preparation for Troubleshooting of Power Train Controller 844
Preparation for Troubleshooting of KOMTRAX Terminal 844
How to Disconnect and Connect Connector with a Special Lock 844
Procedure for Troubleshooting 849
Symptom and Troubleshooting Numbers 852
Information Shown in Troubleshooting Table 855
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 857
Connector List and Layout 860
Connector Contact Connection Table 882
T-Branch Box and T-Branch Adapter Table 922
Fuse Location Table 928
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 932
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135]) 936
Failure Codes Table 938
Troubleshooting by Failure Code (Display of Code) 962
Failure Code [1500L0] 962
Failure Code [15B0NX] 963
Failure Code [15SAL1] 965
Failure Code [15SALH] 967
Failure Code [15SBL1] 969
Failure Code [15SBLH] 971
Failure Code [15SEL1] 973
Failure Code [15SELH] 975
Failure Code [15SFL1] 977
Failure Code [15SFLH] 979
Failure Code [15SGL1] 981
Failure Code [15SGLH] 983
Failure Code [15SJL1] 985
Failure Code [15SJLH] 987
Failure Code [1800MW] 989
Failure Code [2201L1] 990
Failure Code [2201LH] 992
Failure Code [2202L1] 994
Failure Code [2202LH] 995
Failure Code [2300NR] 997
Failure Code [2301L1] 998
Failure Code [2301LH] 1000
Failure Code [2301NR] 1002
Failure Code [2301NT] 1003
Failure Code [2302L1] 1004
Failure Code [2302LH] 1006
Failure Code [2302NR] 1008
Failure Code [2302NT] 1009
Failure Code [851PKA] 1010
Failure Code [851QKA] 1011
Failure Code [851RKA] 1012
Failure Code [851SKA] 1013
Failure Code [851TKA] 1014
Failure Code [851UKA] 1015
Failure Code [851VKA] 1016
Failure Code [851XKA] 1017
Failure Code [852RKR] 1018
Failure Code [8590KA] 1019
Failure Code [8590KY] 1024
Failure Code [879AKA] 1027
Failure Code [879AKB] 1028
Failure Code [879BKA] 1029
Failure Code [879BKB] 1031
Failure Code [879CKA] 1033
Failure Code [879CKB] 1034
Failure Code [879DKZ] 1035
Failure Code [879EMC] 1037
Failure Code [879FMC] 1038
Failure Code [879GKX] 1039
Failure Code [989L00] 1041
Failure Code [989M00] 1042
Failure Code [989N00] 1043
Failure Code [A1U0N3] 1044
Failure Code [A1U0N4] 1046
Failure Code [A900FR] 1048
Failure Code [A900N6] 1049
Failure Code [A900NY] 1050
Failure Code [AA10NX] 1051
Failure Code [AB00KE] 1053
Failure Code [AQ00N3] 1055
Failure Code [AQ00N4] 1056
Failure Code [AQ10N3] 1057
Failure Code [B@BAZG] 1058
Failure Code [B@BAZK] 1059
Failure Code [B@BCNS] 1060
Failure Code [B@BCZK] 1061
Failure Code [B@CENS] 1063
Failure Code [B@HANS] 1065
Failure Code [B@HAZK] 1067
Failure Code [CA115] 1068
Failure Code [CA122] 1072
Failure Code [CA123] 1074
Failure Code [CA131] 1076
Failure Code [CA132] 1078
Failure Code [CA135] 1080
Failure Code [CA141] 1082
Failure Code [CA144] 1084
Failure Code [CA145] 1086
Failure Code [CA153] 1088
Failure Code [CA154] 1090
Failure Code [CA187] 1092
Failure Code [CA212] 1094
Failure Code [CA213] 1096
Failure Code [CA221] 1098
Failure Code [CA222] 1100
Failure Code [CA227] 1102
Failure Code [CA234] 1104
Failure Code [CA238] 1105
Failure Code [CA239] 1107
Failure Code [CA271] 1109
Failure Code [CA272] 1111
Failure Code [CA273] 1112
Failure Code [CA274] 1114
Failure Code [CA322] 1115
Failure Code [CA323] 1117
Failure Code [CA324] 1119
Failure Code [CA325] 1121
Failure Code [CA331] 1123
Failure Code [CA332] 1125
Failure Code [CA343] 1127
Failure Code [CA351] 1129
Failure Code [CA352] 1131
Failure Code [CA356] 1133
Failure Code [CA357] 1135
Failure Code [CA386] 1137
Failure Code [CA441] 1139
Failure Code [CA442] 1141
Failure Code [CA449] 1143
Failure Code [CA451] 1144
Failure Code [CA452] 1146
Failure Code [CA515] 1148
Failure Code [CA516] 1149
Failure Code [CA553] 1150
Failure Code [CA555] 1151
Failure Code [CA556] 1153
Failure Code [CA559] 1155
Failure Code [CA595] 1161
Failure Code [CA687] 1163
Failure Code [CA689] 1165
Failure Code [CA691] 1167
Failure Code [CA692] 1169
Failure Code [CA697] 1171
Failure Code [CA698] 1172
Failure Code [CA731] 1173
Failure Code [CA778] 1177
Failure Code [CA1117] 1179
Failure Code [CA1135] 1181
Failure Code [CA1257] 1184
Failure Code [CA1664] 1185
Failure Code [CA1691] 1187
Failure Code [CA1695] 1190
Failure Code [CA1696] 1192
Failure Code [CA1843] 1194
Failure Code [CA1844] 1196
Failure Code [CA1879] 1198
Failure Code [CA1881] 1200
Failure Code [CA1883] 1202
Failure Code [CA1921] 1205
Failure Code [CA1922] 1207
Failure Code [CA1923] 1211
Failure Code [CA1924] 1213
Failure Code [CA1925] 1215
Failure Code [CA1927] 1217
Failure Code [CA1928] 1219
Failure Code [CA1942] 1221
Failure Code [CA1963] 1223
Failure Code [CA1977] 1227
Failure Code [CA1993] 1229
Failure Code [CA2185] 1232
Failure Code [CA2186] 1234
Failure Code [CA2249] 1236
Failure Code [CA2265] 1241
Failure Code [CA2266] 1243
Failure Code [CA2271] 1245
Failure Code [CA2272] 1247
Failure Code [CA2349] 1249
Failure Code [CA2353] 1251
Failure Code [CA2357] 1253
Failure Code [CA2381] 1256
Failure Code [CA2382] 1258
Failure Code [CA2383] 1260
Failure Code [CA2386] 1262
Failure Code [CA2387] 1264
Troubleshooting Flowchart 1268
Failure Code [CA2637] 1269
Failure Code [CA2639] 1272
Failure Code [CA2732] 1274
Failure Code [CA2733] 1276
Failure Code [CA2741] 1278
Failure Code [CA2765] 1279
Failure Code [CA2777] 1280
Failure Code [CA2878] 1282
Failure Code [CA2881] 1285
Failure Code [CA3133] 1288
Failure Code [CA3134] 1290
Failure Code [CA3135] 1292
Failure Code [CA3167] 1295
Failure Code [CA3251] 1298
Failure Code [CA3253] 1300
Failure Code [CA3254] 1304
Failure Code [CA3255] 1307
Failure Code [CA3256] 1310
Failure Code [CA3311] 1312
Failure Code [CA3312] 1314
Failure Code [CA3313] 1316
Failure Code [CA3314] 1317
Failure Code [CA3315] 1318
Failure Code [CA3316] 1321
Failure Code [CA3317] 1322
Failure Code [CA3318] 1323
Failure Code [CA3319] 1326
Failure Code [CA3321] 1327
Failure Code [CA3322] 1328
Failure Code [CA3419] 1331
Failure Code [CA3421] 1333
Failure Code [CA4151] 1335
Failure Code [CA4158] 1339
Failure Code [CA4161] 1340
Failure Code [CA4162] 1342
Failure Code [CA4163] 1344
Failure Code [CA4259] 1346
Failure Code [CA4952] 1349
Failure Code [CA5383] 1351
Failure Code [CB115] 1352
Failure Code [CB187] 1355
Failure Code [CB227] 1357
Failure Code [CB238] 1358
Failure Code [CB239] 1360
Failure Code [CB271] 1362
Failure Code [CB272] 1364
Failure Code [CB273] 1365
Failure Code [CB274] 1367
Failure Code [CB343] 1368
Failure Code [CB352] 1370
Failure Code [CB386] 1372
Failure Code [CB441] 1374
Failure Code [CB442] 1376
Failure Code [CB689] 1378
Failure Code [CB697] 1380
Failure Code [CB698] 1381
Failure Code [CB731] 1382
Failure Code [CB778] 1386
Failure Code [CB1117] 1388
Failure Code [CB1257] 1390
Failure Code [CB1664] 1391
Failure Code [CB1691] 1393
Failure Code [CB1695] 1396
Failure Code [CB1696] 1398
Failure Code [CB1879] 1400
Failure Code [CB1881] 1402
Failure Code [CB1883] 1404
Failure Code [CB1921] 1407
Failure Code [CB1922] 1409
Failure Code [CB1923] 1413
Failure Code [CB1924] 1415
Failure Code [CB1925] 1417
Failure Code [CB1927] 1419
Failure Code [CB1928] 1421
Failure Code [CB1963] 1423
Failure Code [CB1977] 1427
Failure Code [CB1993] 1429
Failure Code [CB2265] 1432
Failure Code [CB2266] 1434
Failure Code [CB2637] 1436
Failure Code [CB2639] 1439
Failure Code [CB2732] 1441
Failure Code [CB2733] 1443
Failure Code [CB2741] 1445
Failure Code [CB2777] 1447
Failure Code [CB2878] 1449
Failure Code [CB2881] 1452
Failure Code [CB3133] 1455
Failure Code [CB3134] 1457
Failure Code [CB3135] 1459
Failure Code [CB3167] 1462
Failure Code [CB3251] 1465
Failure Code [CB3253] 1467
Failure Code [CB3254] 1472
Failure Code [CB3255] 1475
Failure Code [CB3256] 1478
Failure Code [CB3311] 1480
Failure Code [CB3312] 1482
Failure Code [CB3313] 1484
Failure Code [CB3314] 1485
Failure Code [CB3315] 1486
Failure Code [CB3316] 1489
Failure Code [CB3317] 1490
Failure Code [CB3318] 1491
Failure Code [CB3319] 1494
Failure Code [CB3321] 1495
Failure Code [CB3322] 1496
Failure Code [CB4151] 1499
Failure Code [CB4158] 1503
Failure Code [CB4161] 1504
Failure Code [CB4162] 1506
Failure Code [CB4163] 1508
Failure Code [CB4259] 1511
Failure Code [CB4952] 1514
Failure Code [CB5383] 1516
Failure Code [D130KA] 1517
Failure Code [D130KB] 1519
Failure Code [D141KA] 1520
Failure Code [D141KB] 1522
Failure Code [D141KY] 1524
Failure Code [D162KA] 1526
Failure Code [D162KB] 1528
Failure Code [D162KY] 1530
Failure Code [D16CKA] 1532
Failure Code [D16CKB] 1534
Failure Code [D16CKY] 1535
Failure Code [D182KZ] 1537
Failure Code [D19CKA] 1539
Failure Code [D19CKB] 1541
Failure Code [D19CKY] 1543
Failure Code [D19EKA] 1545
Failure Code [D19EKB] 1547
Failure Code [D19EKY] 1549
Failure Code [D19FKA] 1551
Failure Code [D19FKB] 1553
Failure Code [D19FKY] 1555
Failure Code [D19GKA] 1557
Failure Code [D19GKB] 1559
Failure Code [D19GKY] 1561
Failure Code [D19JKZ] 1563
Failure Code [D1D5KA] 1565
Failure Code [D1D5KB] 1567
Failure Code [D1D5KY] 1569
Failure Code [D1EFKA] 1570
Failure Code [D1EFKB] 1572
Failure Code [D1EWKA] 1574
Failure Code [D1EWKB] 1575
Failure Code [D1EWKY] 1576
Failure Code [D862KA] 1577
Failure Code [DAF0MB] 1578
Failure Code [DAF0MC] 1579
Failure Code [DAF8KB] 1580
Failure Code [DAF9KQ] 1581
Failure Code [DAFGMC] 1582
Failure Code [DAFLKA] 1583
Failure Code [DAFLKB] 1586
Failure Code [DAFQKR] 1588
Failure Code [DAQW00] 1593
Failure Code [DAZ9KQ] 1594
Failure Code [DAZQKR] 1595
Failure Code [DB2QKR] 1599
Failure Code [DB2RKR] 1605
Failure Code [DB90KT] 1610
Failure Code [DB90MC] 1611
Failure Code [DB91KK] 1612
Failure Code [DB92KK] 1615
Failure Code [DB95KK] 1618
Failure Code [DB97KK] 1620
Failure Code [DB99KQ] 1622
Failure Code [DB9LKA] 1623
Failure Code [DB9LKB] 1625
Failure Code [DB9QKR] 1627
Failure Code [DB9RKR] 1632
Failure Code [DBE0KT] 1637
Failure Code [DBE0MC] 1638
Failure Code [DBE1KK] 1639
Failure Code [DBE2KK] 1642
Failure Code [DBE5KK] 1645
Failure Code [DBE6KK] 1647
Failure Code [DBE9KQ] 1649
Failure Code [DBELKA] 1650
Failure Code [DBELKB] 1653
Failure Code [DBEQKR] 1655
Failure Code [DBERKR] 1660
Failure Code [DBV0MC] 1665
Failure Code [DBV1KK] 1666
Failure Code [DBVLKA] 1668
Failure Code [DBVLKB] 1670
Failure Code [DBVQKR] 1672
Failure Code [DBVRKR] 1673
Failure Code [DBVVKR] 1674
Failure Code [DBVWKR] 1675
Failure Code [DD12KA] 1676
Failure Code [DD12KB] 1678
Failure Code [DD13KA] 1680
Failure Code [DD13KB] 1682
Failure Code [DD14KA] 1684
Failure Code [DD14KB] 1686
Failure Code [DDDDKA] 1688
Failure Code [DDDDKB] 1690
Failure Code [DDDDKX] 1692
Failure Code [DDDHKB] 1693
Failure Code [DDDKKA] 1695
Failure Code [DDDKKB] 1697
Failure Code [DDDLKA] 1699
Failure Code [DDDLKB] 1701
Failure Code [DDE2KA] 1703
Failure Code [DDK4KA] 1704
Failure Code [DDK4KB] 1705
Failure Code [DDT5KQ] 1706
Failure Code [DDKAKA] 1707
Failure Code [DDKAKB] 1709
Failure Code [DDKBKA] 1711
Failure Code [DDKBKB] 1713
Failure Code [DDKCL4] 1715
Failure Code [DDKEL4] 1717
Failure Code [DDN7L4] 1719
Failure Code [DDN8L4] 1721
Failure Code [DDNLKA] 1723
Failure Code [DDNLKB] 1725
Failure Code [DDTSL1] 1727
Failure Code [DDTSLH] 1729
Failure Code [DFA4KX] 1731
Failure Code [DFA4KZ] 1732
Failure Code [DFA4L8] 1733
Failure Code [DFA5KA] 1735
Failure Code [DFA5KY] 1737
Failure Code [DFA6KA] 1739
Failure Code [DFA6KY] 1741
Failure Code [DFA7KX] 1743
Failure Code [DFA7KZ] 1744
Failure Code [DFA7L8] 1745
Failure Code [DFA8KA] 1747
Failure Code [DFA8KY] 1749
Failure Code [DFA9KA] 1751
Failure Code [DFA9KY] 1753
Failure Code [DFAAKX] 1755
Failure Code [DFAAKZ] 1756
Failure Code [DFAAL8] 1757
Failure Code [DFABKA] 1759
Failure Code [DFABKY] 1761
Failure Code [DFACKA] 1763
Failure Code [DFACKY] 1765
Failure Code [DGS1KA] 1767
Failure Code [DGS1KX] 1769
Failure Code [DGT1KA] 1771
Failure Code [DGT1KX] 1773
Failure Code [DGT4KA] 1775
Failure Code [DGT4KY] 1777
Failure Code [DH21KA] 1779
Failure Code [DH21KY] 1781
Failure Code [DHA4KA] 1783
Failure Code [DHAAMA] 1785
Failure Code [DHABMA] 1786
Failure Code [DHACMA] 1787
Failure Code [DHADMA] 1788
Failure Code [DHT2L6] 1789
Failure Code [DHT3KX] 1790
Failure Code [DHT5KA] 1791
Failure Code [DHT5KY] 1793
Failure Code [DHT7KA] 1795
Failure Code [DHT7KY] 1797
Failure Code [DK10KA] 1799
Failure Code [DK10KB] 1801
Failure Code [DK30KA] 1803
Failure Code [DK30KX] 1805
Failure Code [DK30KY] 1806
Failure Code [DK30KZ] 1808
Failure Code [DK30L8] 1809
Failure Code [DK31KA] 1811
Failure Code [DK31KY] 1813
Failure Code [DK40KA] 1815
Failure Code [DK40KY] 1817
Failure Code [DK55KX] 1819
Failure Code [DK55KZ] 1820
Failure Code [DK55L8] 1821
Failure Code [DK56KA] 1822
Failure Code [DK56KY] 1824
Failure Code [DK57KA] 1826
Failure Code [DK57KY] 1828
Failure Code [DK60KA] 1830
Failure Code [DK60KY] 1832
Failure Code [DKH1KA] 1834
Failure Code [DKH1KY] 1836
Failure Code [DKW0KX] 1838
Failure Code [DKW0KZ] 1839
Failure Code [DKW0L8] 1840
Failure Code [DKW1KA] 1841
Failure Code [DKW1KY] 1843
Failure Code [DKW2KA] 1845
Failure Code [DKW2KY] 1847
Failure Code [DKW3KX] 1849
Failure Code [DKW3KZ] 1850
Failure Code [DKW3L8] 1851
Failure Code [DKW4KA] 1852
Failure Code [DKW4KY] 1854
Failure Code [DKW5KA] 1856
Failure Code [DKW5KY] 1858
Failure Code [DLM3KA] 1860
Failure Code [DLM3MB] 1861
Failure Code [DLT3KA] 1862
Failure Code [DLT3KB] 1864
Failure Code [DNDAMC] 1866
Failure Code [DNDBKA] 1868
Failure Code [DNDBKB] 1870
Failure Code [DNDCKA] 1872
Failure Code [DNDCKB] 1874
Failure Code [DNDDKA] 1876
Failure Code [DNDDKB] 1878
Failure Code [DNDEKA] 1880
Failure Code [DNDEKB] 1882
Failure Code [DR21KX] 1884
Failure Code [DR31KX] 1885
Failure Code [DV20KB] 1886
Failure Code [DW7BKA] 1888
Failure Code [DW7BKB] 1890
Failure Code [DWN3KA] 1891
Failure Code [DWN3KB] 1893
Failure Code [DWN3KY] 1895
Failure Code [DWN5KA] 1896
Failure Code [DWN5KB] 1898
Failure Code [DWN5KY] 1900
Failure Code [DWNCKA] 1901
Failure Code [DWNCKB] 1903
Failure Code [DWNCKY] 1904
Failure Code [DWNVKA] 1905
Failure Code [DWNVKB] 1907
Failure Code [DWNWKA] 1909
Failure Code [DWNWKB] 1911
Failure Code [DWNXKA] 1913
Failure Code [DWNXKB] 1915
Failure Code [DWNYKA] 1917
Failure Code [DWNYKB] 1919
Failure Code [DXH1KA] 1921
Failure Code [DXH1KB] 1923
Failure Code [DXH1KY] 1925
Failure Code [DXH4KA] 1926
Failure Code [DXH4KB] 1928
Failure Code [DXH4KY] 1930
Failure Code [DXH5KA] 1931
Failure Code [DXH5KB] 1933
Failure Code [DXH5KY] 1935
Failure Code [DXH6KA] 1936
Failure Code [DXH6KB] 1938
Failure Code [DXH6KY] 1940
Failure Code [DXH7KA] 1941
Failure Code [DXH7KB] 1943
Failure Code [DXH7KY] 1945
Failure Code [DXH8KA] 1946
Failure Code [DXH8KB] 1948
Failure Code [DXH8KY] 1950
Failure Code [DXH9KA] 1951
Failure Code [DXH9KB] 1953
Failure Code [DXH9KY] 1955
Failure Code [DXHAKA] 1956
Failure Code [DXHAKB] 1958
Failure Code [DXHAKY] 1960
Failure Code [DXHBKA] 1961
Failure Code [DXHBKB] 1963
Failure Code [DXHBKY] 1965
Failure Code [DXHCKA] 1966
Failure Code [DXHCKB] 1968
Failure Code [DXHCKY] 1970
Failure Code [DXHRKA] 1971
Failure Code [DXHRKB] 1973
Failure Code [DXHRKY] 1975
Failure Code [DXHSKA] 1976
Failure Code [DXHSKB] 1978
Failure Code [DXHSKY] 1980
Failure Code [DXHTKA] 1981
Failure Code [DXHTKB] 1983
Failure Code [DXHTKY] 1985
Failure Code [DXHUKA] 1986
Failure Code [DXHUKB] 1988
Failure Code [DXHUKY] 1990
Failure Code [DXHWKA] 1991
Failure Code [DXHWKB] 1993
Failure Code [DXHWKY] 1995
Failure Code [DXHXKA] 1996
Failure Code [DXHXKB] 1998
Failure Code [DXHXKY] 2000
Failure Code [DXHYKA] 2001
Failure Code [DXHYKB] 2003
Failure Code [DXHYKY] 2005
Failure Code [DXHZKA] 2006
Failure Code [DXHZKB] 2008
Failure Code [DXHZKY] 2010
Failure Code [DXJ4KA] 2011
Failure Code [DXJ4KB] 2013
Failure Code [DXJ8KA] 2014
Failure Code [DXJ8KB] 2016
Failure Code [DXJ8KY] 2018
Failure Code [DXJ9KA] 2019
Failure Code [DXJ9KB] 2021
Failure Code [DXJ9KY] 2023
Failure Code [DXJBKA] 2024
Failure Code [DXJBKB] 2026
Failure Code [DXJBKY] 2027
Failure Code [DY2HKA] 2028
Failure Code [F9A0KT] 2030
Failure Code [F9A0MC] 2031
Failure Code [F9A1KK] 2032
Failure Code [F9A2KK] 2034
Failure Code [F9AQKR] 2036
Failure Code [F9ARKR] 2041
Failure Code [F9ATKA] 2046
Failure Code [F9ATKB] 2049
Failure Code [F9AUMC] 2051
Failure Code [F@BYNR] 2053
Failure Code [F@BYNS] 2054
Troubleshooting of Electrical System (E-Mode) 2055
E-1 Engine Does Not Start (Engine Does Not Crank) 2055
E-2 Engine Does Not Start in Radio Control Mode (Engine Does Not Crank) 2059
E-3 Engine Stops During Operation (Specifications of Radio Control) 2062
E-4 Manual Preheating System Does Not Work 2067
E-5 Automatic Preheating System Does Not Work 2070
E-6 While Preheating is in Operation, Preheating Monitor Does Not Come On 2072
E-7 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 2074
E-8 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 2078
E-9 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 2080
E-10 Charge Level Monitor Comes On in Red While Engine Runs 2081
E-11 Engine Coolant Temperature Monitor Comes on in Red While Engine is in Operation 2083
E-12 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 2084
E-13 Power Train Oil Temperature Monitor Comes On in Red While Engine Runs 2085
E-14 Hydraulic Oil Temperature Monitor Comes on in Red While Engine Runs 2086
E-15 Engine Coolant Temperature Gauge Does Not Show Correct Temperature 2087
E-16 Fuel Level Gauge Does Not Show Correct Level 2088
E-17 Power Train Oil Temperature Gauge Does Not Show Correct Temperature 2090
E-18 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 2092
E-19 Operation Mode Does Not Change 2094
E-20 Gear Shift Mode Does Not Change 2095
E-21 Movement of Machine Does Not Align to Instructions in Radio Control Transmitter Operation 2096
E-22 Radio Control/on-Board Can Not be Changed 2099
E-23 All Radio Control Can Not be Operated 2103
E-24 Operating Customize Switch Does Not Display Customize Screen 2106
E-25 Modifying Setting on Customize Screen Does Not Change Setting of Machine 2107
E-26 Some Areas of Machine Monitor Screen are Not Shown 2108
E-27 Alarm Buzzer Does Not Sound or Cannot be Stopped 2109
E-28 Service Meter is Not Shown, While Starting Switch is in OFF Position 2110
E-29 Service Mode Cannot be Selected 2111
E-30 Horn Does Not Sound 2112
E-31 Horn Does Not Stop 2114
E-32 Horn Does Not Sound or Does Not Stop (Specifications of Radio Control) 2115
E-33 Backup Alarm Does Not Sound 2117
E-34 Backup Alarm Does Not Stop 2118
E-35 Headlamp Does Not Come On 2119
E-36 Rear Lamp and Ripper Point Lamp Do Not Come On 2123
E-37 Working Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2127
E-38 Red Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2130
E-39 Blue Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2133
E-40 Green Revolving Lamp Does Not Come On or Go Out (Specifications of Radio Control) 2136
E-41 No Wiper Operates 2139
E-42 Front Wiper Does Not Operate 2144
E-43 Rear Wiper Does Not Operate 2148
E-44 Left Door Wiper Does Not Operate 2152
E-45 Right Door Wiper Does Not Operate 2156
E-46 Fuel Feed Pump Does Not Operate or Stop Automatically 2160
E-47 Fan Does Not Rotate in Reverse 2162
E-48 Gear Cannot be Shifted 2163
E-49 Front Washer Does Not Operate 2164
E-50 Rear Washer Does Not Operate 2166
E-51 Left Door Washer Does Not Operate 2168
E-52 Right Door Washer Does Not Operate 2170
E-53 Ripper Pin Puller Does Not Work 2172
E-54 KOMTRAX Plus System Does Not Operate Normally 2174
E-55 Cannot Download Data with Wireless LAN 2175
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2176
Information Shown in Troubleshooting Table (H-Mode) 2176
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull) 2177
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2180
H-3 Machine Does Not Move Off at All Gear Speeds 2182
H-4 Machine Travels Only in One Direction, Forward or in Reverse 2184
H-5 Large Time Lag is in Gear Shifting or Directional Change 2185
H-6 Brake Does Not Work 2187
H-7 Power Train Oil Overheats 2188
H-8 Torque Converter Lockup Clutch Does Not Engage 2189
H-9 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) 2190
H-10 Machine Can Turn (Steering) Only in One Direction 2191
H-11 Machine Falls Over Too Much (Steering) 2192
H-12 All Work Equipment Operate Slowly 2193
H-13 All Work Equipment Do Not Operate 2195
H-14 Blade Lift Speed or Power is Low 2197
H-15 Blade Tilt Speed or Power is Low 2199
H-16 Ripper Lift Speed or Power is Low 2201
H-17 Ripper Tilt Speed or Power is Low 2203
H-18 Hydraulic Drift of Blade Lift is Large 2205
H-19 Hydraulic Drift of Tilted Blade is Large 2206
H-20 Hydraulic Drift of Lifted Ripper is Large 2207
H-21 Ripper Pin Puller Cylinder Does Not Operate 2208
H-22 Blade Pitch Cylinder Does Not Operate 2209
H-23 Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 2210
H-24 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2211
H-25 Seismic Isolation Operator Seat Shakes Abnormally or Receives Shock 2212
Troubleshooting of Engine (S-Mode) 2213
Information Shown in Troubleshooting Table (S-Mode) 2213
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2214
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2215
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2216
S-4 Engine Startability is Unsatisfactory 2217
S-5 Engine Does Not Pick Up Smoothly 2219
S-6 Engine Stops During Operation 2221
S-7 Engine Runs Rough or is Not Stable 2223
S-8 Engine Lacks Power 2224
S-9 KDPF Becomes Clogged in a Short Time 2226
S-10 Engine Oil Consumption is Excessive 2228
S-11 Oil Becomes Dirty Quickly 2229
S-12 Fuel Consumption is Excessive 2230
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2231
S-14 Oil Pressure Drops 2232
S-15 Fuel Mixes Into Engine Oil 2234
S-16 Water Mixes Into Engine Oil (Milky) 2235
S-17 Coolant Temperature Increases Too High (Overheating) 2236
S-18 Unusual Noise is Heard 2238
S-19 Vibration is Excessive 2239
S-20 Air Cannot be Bled from Fuel Circuit 2240
S-21 Active Regeneration is Done Frequently 2241
S-22 Active Regeneration Continues Long 2242
S-23 White Smoke is Exhausted During Active Regeneration 2243
50 Disassembly and Assembly 2245
Table of Contents 2246
Precautions Before Work 2252
Related Information on Disassembly and Assembly 2253
How to Read This Manual 2253
Coating Materials List 2255
Special Tool List 2260
Sketches of Special Tools 2285
Engine and Cooling System 2311
Remove and Install Supply Pump Assembly 2311
How to Remove Supply Pump Assembly 2311
How to Install Supply Pump Assembly 2319
Remove and Install Injector Assembly 2330
How to Remove Injector Assembly 2331
How to Install Injector Assembly 2339
Remove and Install Fuel Doser Assembly 2352
How to Remove Fuel Doser Assembly 2352
How to Install Fuel Doser Assembly 2354
Remove and Install Cylinder Head Assembly 2357
How to Remove Cylinder Head Assembly 2358
How to Install Cylinder Head Assembly 2380
Remove and Install Common Rail 2411
How to Remove Common Rail 2411
How to Install Common Rail 2417
Remove and Install EGR Valve Assembly 2424
How to Remove EGR Valve Assembly 2424
How to Install EGR Valve Assembly 2425
Remove and Install EGR Cooler Assembly 2426
How to Remove EGR Cooler Assembly 2426
How to Install EGR Cooler Assembly 2431
Remove and Install Starter Assembly 2436
How to Remove Starting Motor Assembly 2436
How to Install Starting Motor Assembly 2437
Remove and Install Radiator Guard Assembly 2439
How to Remove Radiator Guard Assembly 2439
How to Install Radiator Guard Assembly 2445
Remove and Install Cooler Assembly 2452
How to Remove Cooling Assembly 2452
How to Install Cooling Assembly 2457
Remove and Install Radiator Assembly 2461
How to Remove Radiator Assembly 2461
How to Install Radiator Assembly 2463
Remove and Install Hydraulic Oil Cooler Assembly 2465
How to Remove Hydraulic Oil Cooler Assembly 2465
How to Install Hydraulic Oil Cooler Assembly 2467
Remove and Install Aftercooler Assembly 2469
How to Remove Aftercooler Assembly 2469
How to Install Aftercooler Assembly 2471
Open and Close Cooling Fan Drive Assembly 2473
How to Open Cooling Fan Drive Assembly 2473
How to Close Cooling Fan Drive Assembly 2476
Remove and Install Cooling Fan Drive Assembly 2479
How to Remove Cooling Fan Drive Assembly 2479
How to Install Cooling Fan Drive Assembly 2483
Remove and Install Cooling Fan Motor Assembly 2486
How to Remove Cooling Fan Motor Assembly 2486
How to Install Cooling Fan Motor Assembly 2488
Remove and Install Engine Assembly 2490
How to Remove Engine Assembly 2490
How to Install Engine Assembly 2503
Remove and Install Engine Front Oil Seal 2516
How to Remove Engine Front Oil Seal 2516
How to Install Engine Front Oil Seal 2517
Remove and Install Engine Rear Oil Seal 2519
How to Remove Engine Rear Oil Seal 2519
How to Install Engine Rear Oil Seal 2520
Remove and Install Engine Hood Assembly 2524
How to Remove Engine Hood Assembly 2524
How to Install Engine Hood Assembly 2529
Remove and Install Fuel Tank Assembly 2536
How to Remove Fuel Tank Assembly 2536
How to Install Fuel Tank Assembly 2540
Remove and Install KDPF Assembly 2545
How to Remove KDPF Assembly 2545
How to Install KDPF Assembly 2550
Disassemble and Assemble KDPF Assembly 2555
How to Disassemble KDPF Assembly 2556
How to Assemble KDPF Assembly 2561
Remove and Install KCCV Assembly 2568
How to Remove KCCV Assembly 2568
How to Install KCCV Assembly 2570
Remove and Install VGT Assembly 2574
How to Remove VGT Assembly 2574
How to Install VGT Assembly 2582
Remove and Install Air Cleaner Bracket Assembly 2592
How to Remove Air Cleaner Bracket Assembly 2592
How to Install Air Cleaner Bracket Assembly 2597
Remove and Install Air Cleaner Assembly 2602
How to Remove Air Cleaner Assembly 2602
How to Install Air Cleaner Assembly 2603
Remove and Install Air Conditioner Compressor Assembly 2604
How to Remove Air Conditioner Compressor Assembly 2604
How to Install Air Conditioner Compressor Assembly 2607
Remove and Install Air Conditioner Condenser Assembly 2610
How to Remove Air Conditioner Condenser Assembly 2610
How to Install Air Conditioner Condenser Assembly 2613
Power Train 2616
Remove and Install Damper Assembly 2616
How to Remove Damper Assembly 2616
How to Install Damper Assembly 2624
Disassemble and Assemble Damper Assembly 2634
How to Disassemble Damper Assembly 2634
How to Assemble Damper Assembly 2635
Remove and Install Power Train Unit Assembly 2638
How to Remove Power Train Unit Assembly 2638
How to Install Power Train Unit Assembly 2651
Disconnect and Connect Power Train Unit Assembly 2664
How to Disconnect Power Train Unit Assembly 2664
How to Connect Power Train Unit Assembly 2673
Disassemble and Assemble PTO Assembly 2683
How to Disassemble PTO Assembly 2683
How to Assemble PTO Assembly 2686
Disassemble and Assemble Torque Converter Assembly 2691
How to Disassemble Torque Converter Assembly 2691
How to Assemble Torque Converter Assembly 2695
Disassemble and Assemble Transmission Assembly 2702
How to Disassemble Transmission Assembly 2703
How to Assemble Transmission Assembly 2715
Disassemble and Assemble Steering Case Assembly 2733
How to Disassemble Steering Case Assembly 2733
How to Assemble Steering Case Assembly 2740
Remove and Install Final Drive Assembly 2750
How to Remove Final Drive Assembly 2750
How to Install Final Drive Assembly 2751
Disassemble and Assemble Final Drive Assembly 2753
How to Disassemble Final Drive Assembly 2754
How to Assemble Final Drive Assembly 2760
Undercarriage and Frame 2770
Remove and Install Track Frame Assembly 2770
How to Remove Track Frame Assembly 2770
How to Install Track Frame Assembly 2774
Remove and Install Idler Assembly 2779
How to Remove Idler Assembly 2779
How to Install Idler Assembly 2780
Disassemble and Assemble Idler Assembly 2781
How to Disassemble Idler Assembly 2781
How to Assemble Idler Assembly 2782
Remove and Install Recoil Spring Assembly 2785
How to Remove Recoil Spring Assembly 2786
How to Install Recoil Spring Assembly 2794
Disassemble and Assemble Recoil Spring Assembly 2799
How to Disassemble Recoil Spring Assembly 2799
How to Assemble Recoil Spring Assembly 2800
Remove and Install Track Roller Assembly 2801
How to Remove Track Roller Assembly 2801
How to Install Track Roller Assembly 2803
Disassemble and Assemble Track Roller Assembly 2805
How to Disassemble Track Roller Assembly 2805
How to Assemble Track Roller Assembly 2806
Remove and Install No 1 Bogie Assembly 2808
How to Remove No 1 Bogie Assembly 2809
How to Install No 1 Bogie Assembly 2811
Remove and Install Bogie Assembly 2814
How to Remove Bogie Assembly 2815
How to Install Bogie Assembly 2818
Disassemble and Assemble Bogie Assembly 2820
How to Disassemble Bogie Assembly 2820
How to Assemble Bogie Assembly 2821
Remove and Install Carrier Roller Assembly 2823
How to Remove Carrier Roller Assembly 2823
How to Install Carrier Roller Assembly 2823
Disassemble and Assemble Carrier Roller Assembly 2825
How to Disassemble Carrier Roller Assembly 2825
How to Assemble Carrier Roller Assembly 2826
Remove and Install Pivot Shaft Assembly 2830
How to Remove Pivot Shaft Assembly 2830
How to Install Pivot Shaft Assembly 2831
Separate and Connect Track Assembly 2832
How to Separate Track Assembly 2832
How to Install Track Assembly 2834
Disassemble and Assemble Track Assembly Generally 2836
How to Disassemble Full Track Shoes Assembly 2836
How to Assemble Full Track Shoes Assembly 2839
Disassemble and Assemble One Track Link Assembly in Field 2853
How to Disassemble One Track Link Assembly in Field 2854
How to Assemble One Track Link Assembly in Field 2856
Disassemble and Assemble Master Link 2858
How to Disassemble Master Link 2860
How to Assemble Master Link 2860
Remove and Install Equalizer Bar Assembly 2863
How to Remove Equalizer Bar Assembly 2863
How to Install Equalizer Bar Assembly 2868
Disassemble and Assemble Equalizer Bar Bushing 2873
How to Disassemble Equalizer Bar Bushing 2873
How to Assemble Equalizer Bar Bushing 2874
Remove and Install Segment Teeth 2876
How to Remove Segment Teeth 2876
How to Install Segment Teeth 2876
Remove and Install Power Ladder Assembly 2878
How to Remove Power Ladder Assembly 2878
How to Install Power Ladder Assembly 2881
Open and Close Underguard Assembly 2884
How to Open Underguard Assembly 2884
How to Close Underguard Assembly 2890
Remove and Install Under Guard Assembly 2896
How to Remove Underguard Assembly 2896
How to Install Underguard Assembly 2903
Hydraulic System 2909
Remove and Install Hydraulic Tank Assembly 2909
How to Remove Hydraulic Tank Assembly 2909
How to Install Hydraulic Tank Assembly 2913
Remove and Install Work Equipment Pump Assembly 2918
How to Remove Work Equipment Pump Assembly 2918
How to Install Work Equipment Pump Assembly 2922
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2927
How to Remove Power Train Pump and Steering Lubrication Pump Assembly 2927
How to Install Power Train Pump and Steering Lubrication Pump Assembly 2927
Remove and Install Cooling Fan Pump Assembly 2929
How to Remove Cooling Fan Pump Assembly 2929
How to Install Cooling Fan Pump Assembly 2930
Remove and Install Scavenging Pump Assembly 2932
How to Remove Scavenging Pump Assembly 2932
How to Install Scavenging Pump Assembly 2932
Disassemble and Assemble Control Valve Assembly 2934
How to Assemble Control Valve Assembly 2934
Remove and Install Control Valve Assembly 2937
How to Remove Control Valve Assembly 2937
How to Install Control Valve Assembly 2943
Work Equipment 2950
Remove and Install Blade Assembly 2950
How to Remove Blade Assembly 2950
How to Install Blade Assembly 2953
Remove and Install Blade Lift Cylinder Assembly 2957
How to Remove Blade Lift Cylinder Assembly 2958
How to Install Blade Lift Cylinder Assembly 2963
Disassemble and Assemble Blade Assembly 2968
How to Disassemble Blade Assembly 2968
How to Assemble Blade Assembly 2971
Disassemble and Assemble Giant Ripper Assembly 2975
How to Disassemble Giant Ripper Assembly 2975
How to Assemble Giant Ripper Assembly 2977
Disassemble and Assemble Blade Lift Cylinder Assembly 2980
How to Disassemble Blade Lift Cylinder Assembly 2980
How to Assemble Blade Lift Cylinder Assembly 2983
Disassemble and Assemble Blade Tilt Cylinder Assembly 2987
How to Disassemble Blade Tilt Cylinder Assembly 2987
How to Assemble Blade Tilt Cylinder Assembly 2989
Disassemble and Assemble Ripper Pin Puller Cylinder Assembly 2992
How to Disassemble Ripper Pin Puller Cylinder Assembly 2992
How to Assemble Ripper Pin Puller Cylinder Assembly 2993
CAB Related Parts 2995
Remove and Install ROPS Guard 2995
How to Remove ROPS Guard 2995
How to Install ROPS Guard 2996
Remove and Install Operator Cab Assembly 2997
How to Remove Operator Cab Assembly 2997
How to Install Operator Cab Assembly 3001
Remove and Install Operator Cab Glass (Adhered Glass) 3005
How to Remove Operator Cab Glass (Adhered Glass) 3006
How to Install Operator Cab Glass (Adhered Glass) 3006
Remove and Install Air Conditioner Unit Assembly 3010
How to Remove Air Conditioner Unit Assembly 3010
How to Install Air Conditioner Unit Assembly 3016
Remove and Install Operator Seat 3022
How to Remove Operator Seat 3022
How to Install Operator Seat 3023
How to Remove and Install Seat Belt 3025
How to Remove Seat Belt 3025
How to Install Seatbelt 3026
Remove and Install FCCS 3027
How to Remove FCCS 3027
How to Install FCCS 3028
Electrical System 3030
Remove and Install Engine Controller Assembly 3030
How to Remove Engine Controller Assembly 3030
How to Install Engine Controller Assembly 3034
Remove and Install Power Train Controller Assembly 3039
How to Remove Power Train Controller Assembly 3039
How to Install Power Train Controller Assembly 3040
Remove and Install Work Equipment Controller Assembly 3041
How to Remove Work Equipment Controller Assembly 3041
How to Install Work Equipment Controller Assembly 3042
Remove and Install Machine Monitor Assembly 3043
How to Remove Machine Monitor Assembly 3043
How to Install Machine Monitor Assembly 3044
Remove and Install Mass Air Flow and Temperature Sensor 3046
How to Remove Mass Air Flow and Temperature Sensor 3046
How to Install Mass Air Flow and Temperature Sensor 3047
Remove and Install KCCV Crankcase Pressure Sensor 3049
How to Remove KCCV Crankcase Pressure Sensor 3049
How to Install KCCV Crankcase Pressure Sensor 3050
Remove and Install KOMTRAX Terminal Assembly 3051
How to Remove KOMTRAX Terminal Assembly 3051
How to Install KOMTRAX Terminal Assembly 3051
Remove And Install KOMTRAX Plus Controller Assembly 3053
How to Remove KOMTRAX Plus Controller Assembly 3053
How to Install KOMTRAX Plus Controller Assembly 3054
Remove and Install Wireless LAN Unit Assembly 3056
How to Remove Wireless LAN Unit Assembly 3056
How to Install Wireless LAN Unit Assembly 3057
Remove and Install Option Controller Assembly 3059
How to Remove Option Controller Assembly 3059
How to Install Option Controller Assembly 3062
Remove and Install Radio Control Receiver 3067
How to Remove Radio Control Receiver 3067
How to Install Radio Control Receiver 3068
60 Maintenance Standard 3071
Table of Contents 3072
Engine and Cooling System 3073
Maintenance Standard for Engine Mount 3073
Maintenance Standard for Damper 3075
Maintenance Standard for Cooling System 3077
Maintenance Standard for Cooling Fan Pump 3079
Maintenance Standard for Servo Valve 3087
Maintenance Standard for Cooling Fan Motor 3089
Power Train 3092
Maintenance Standard for Universal Joint 3092
Maintenance Standard for Power Train Mount 3093
Maintenance Standard for Torque Converter and PTO 3095
Maintenance Standard for Torque Converter Control Valve 3100
Maintenance Standard for Lockup Clutch ECMV 3102
Maintenance Standard for Stator Clutch ECMV 3103
Maintenance Standard for Transmission 3104
Maintenance Standard for PTO, Transmission Lubrication Pump, and Power Train Pump 3110
Maintenance Standard for Transmission ECMV 3112
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 3113
Maintenance Standard for Transmission Lubrication Relief Valve 3114
Maintenance Standard for Transfer, Bevel Gear Shaft, and Steering 3115
Maintenance Standard for Brake Solenoid Valve 3121
Maintenance Standard for Sudden Stop Prevention Valve 3122
Maintenance Standard for Final Drive 3123
Maintenance Standard for Sprocket for Conventional Type Track Shoes 3127
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 3128
Undercarriage and Frame 3130
Maintenance Standard for Main Frame 3130
Maintenance Standard for Suspension 3133
Maintenance Standard for Track Frame and Idler Cushion 3136
Maintenance Standard for Idler 3140
Maintenance Standard for Track Roller Bogie 3142
Maintenance Standard for Track Roller for Conventional Type Track Shoes 3143
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 3146
Maintenance Standard for Conventional Type Track Shoes 3147
Maintenance Standard for Single Shoes and Heavy Duty Shoes 3149
Hydraulic System 3150
Maintenance Standard for Hydraulic Tank 3150
Maintenance Standard for Work Equipment Pump 3151
Maintenance Standard for Scavenging Pump 3154
Maintenance Standard for Control Valve 3155
Maintenance Standard for Self-Pressure Reducing Valve 3165
Maintenance Standard for Quick Drop Valve 3168
Work Equipment 3169
Maintenance Standard for Cylinder Stay 3169
Maintenance Standard for Front Work Equipment 3170
Maintenance Standard for Cutting Edge and End Bit 3176
Maintenance Standard for Blade Lift Cylinder 3177
Maintenance Standard for Blade Tilt Cylinder 3179
Maintenance Standard for Variable Multi-Shank Ripper 3181
Maintenance Standard for Variable Giant Ripper 3183
Maintenance Standard for Ripper Lift Cylinder 3185
Maintenance Standard for Ripper Tilt Cylinder 3186
CAB Related Parts 3187
Maintenance Standard for CAB Mount 3187
Maintenance Standard for ROPS 3188
80 Appendix 3189
Table of Contents 3190
Precautions Before Work 3192
Air Conditioner System 3193
Precautions for Refrigerant 3193
Air Conditioner Component 3194
Specifications of Air Conditioner 3196
Structure and Function of Refrigeration Cycle 3197
Outline of Refrigeration Cycle 3198
Component Parts of Air Conditioner System 3200
Air Conditioner Unit 3200
Configuration Diagram of Air Conditioner Unit 3200
Function of Air Conditioner Unit 3202
Component Parts of Air Conditioner Unit 3204
Function of Evaporator as Air Conditioner Unit Component 3205
Function of Heater Core as Air Conditioner Unit Component 3205
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3205
Function of Servo Motor as Air Conditioner Unit Component 3205
Structure of Expansion Valve as Air Conditioner Unit Component 3206
Function of Expansion Valve as Air Conditioner Unit Component 3206
Operate Expansion Valve as Air Conditioner Unit Component 3206
Function of Triple Pressure Switch 3207
Air Conditioner Controller 3208
Structure of Air Conditioner Controller 3208
Compressor 3209
Structure of Compressor 3209
Specifications of Compressor 3209
Function of Compressor 3209
Condenser 3210
Structure of Condenser 3210
Specifications of Condenser 3210
Function of Condenser 3210
Receiver Drier 3211
Structure of Receiver Dryer 3211
Specifications of Receiver Dryer 3211
Function of Receiver Dryer 3211
Air Conditioner Related Sensors 3212
Structure of Sunlight Sensor 3212
Function of Sunlight Sensor 3212
Structure of Outside Temperature Sensor 3212
Function of Outside Air Temperature Sensor 3212
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3214
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3216
System Diagram of Air Conditioner 3218
Input and Output Signals of Air Conditioner Controller 3219
Function of Air Conditioner Controller 3220
Locations of Air Conditioner Parts and Layout of Connectors 3221
Examine Air Leakage (Duct) 3230
How to Examine Air Leakage (Duct) 3230
Examine Air Conditioner with Self-Diagnosis Function 3233
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3234
Examine Vent (Mode) Changeover 3235
How to Examine Vent (Mode) Changeover 3235
Examine Fresh/Recirc Air Changeover 3236
How to Examine Fresh/Recirc Air Changeover 3236
Examine Sunlight Sensor 3237
How to Examine Sunlight Sensor 3237
Examine Refrigerant (Triple) Pressure Switch 3238
How to Examine Refrigerant (Triple) Pressure Switch 3238
Examine Relay 3239
How to Examine Relay 3239
Air Conditioner Troubleshooting Chart 1 3240
Air Conditioner Troubleshooting Chart 2 3241
Information Shown in Troubleshooting Table 3244
Failure Code [879AKA] 3245
Failure Code [879AKB] 3246
Failure Code [879BKA] 3247
Failure Code [879BKB] 3249
Failure Code [879CKA] 3251
Failure Code [879CKB] 3252
Failure Code [879DKZ] 3253
Failure Code [879EMC] 3255
Failure Code [879FMC] 3256
Failure Code [879GKX] 3257
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3259
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3261
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3265
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3267
Troubleshooting by Gauge Pressure 3269
Connect Service Tool 3272
How to Connect Service Tool 3272
Precautions for Disconnection and Connection of Air Conditioner Piping 3274
Handle Compressor Oil 3276
90 Circuit Diagrams 3279
Table of Contents 3280
Hydraulic Circuit Diagram 3281
Symbols Used in Hydraulic Circuit Diagram 3281
Hydraulic Circuit Diagram 3285
Power Train Hydraulic Circuit Diagram 3287
Electrical Circuit Diagram 3289
Symbols Used in Electric Circuit Diagram 3289
Electrical Circuit Diagram (1/12) 3293
Electrical Circuit Diagram (2/12) 3295
Electrical Circuit Diagram (3/12) 3297
Electrical Circuit Diagram (4/12) 3299
Electrical Circuit Diagram (5/12) 3301
Electrical Circuit Diagram (6/12) 3303
Electrical Circuit Diagram (7/12) 3305
Electrical Circuit Diagram (8/12) 3307
Electrical Circuit Diagram (9/12) 3309
Electrical Circuit Diagram (10/12) 3311
Electrical Circuit Diagram (11/12) 3313
Electrical Circuit Diagram (12/12) 3315
Electrical Circuit Diagram of Inside of CAB (1/14) 3317
Electrical Circuit Diagram of Inside of CAB (2/14) 3319
Electrical Circuit Diagram of Inside of CAB (3/14) 3321
Electrical Circuit Diagram of Inside of CAB (4/14) 3323
Electrical Circuit Diagram of Inside of CAB (5/14) 3325
Electrical Circuit Diagram of Inside of CAB (6/14) 3327
Electrical Circuit Diagram of Inside of CAB (7/14) 3329
Electrical Circuit Diagram of Inside of CAB (8/14) 3331
Electrical Circuit Diagram of Inside of CAB (9/14) 3333
Electrical Circuit Diagram of Inside of CAB (10/14) 3335
Electrical Circuit Diagram of Inside of CAB (11/14) 3337
Electrical Circuit Diagram of Inside of CAB (12/14) 3339
Electrical Circuit Diagram of Inside of CAB (13/14) 3341
Electrical Circuit Diagram of Inside of CAB (14/14) 3343
Index 3345

DESCRIPTION:

Komatsu D375A-8 Bulldozer Shop Manual SEN06708-09 – PDF DOWNLOAD

SERIAL NUMBERS 80001 and up

Foreword, Safety, Basic Information
How to Read the Shop Manual
• Some of the attachments and options described in this shop manual may not be available in some areas. If
they are required, consult your Komatsu distributor.
• The materials and specifications are subject to change without notice.
• Shop Manuals are available for “machine part” and “engine part”. For the engine unit, see the shop manual
for the machine which has the same engine model.
• Actual machine may differ from the images which are contained in this manual. A typical model is shown in
the illustrations of this shop manual.
• The caution lamps, pilot lamps, and symbols of the switches on the machine monitor can be different in
accordance with the machine.
• For details of the symbols shown on the machine monitor, see Structure and Operation, “Caution
Lamps Shown on Machine Monitor” and “Pilot Lamps Shown on Machine Monitor”.
• For details of the switches of the machine monitor, see Testing and Adjusting, “Set and Operate Machine
Monitor”.
• For details of the switches, see the “Operation and Maintenance Manual”.
• All “AdBlue/DEF” shown on the machine monitor is referred to as “DEF” in the shop manual. Some machine
monitors installed to the product show “DEF” as “AdBlue/DEF” in the service mode. Thus, be sure to recognize
that “DEF” and “AdBlue/DEF” are the same when you read the shop manual.
Composition of the Shop Manual
This shop manual contains technical information necessary to perform services in workshops. It is divided into
the following chapters for the ease of use.
00 Index and Foreword
This section describes the index, foreword, safety, and basic information.
01 Specification
This section describes the specifications of the machine.
10 Structure and Function
This section describes the structure and operation of each component with respect to each system. “Structure
and Function” is helpful in not only understanding the structure of each component but performing troubleshooting.
20 Standard Value Table
This section describes the standard values for new machine and failure criteria for testing and adjusting, and
troubleshooting. Use the standard values table to check the standard values for testing and adjusting, and judge
troubles in troubleshooting.
30 Testing and Adjusting
This section describes the measuring tools and measuring methods for testing and adjusting as well as the adjusting
method of each part. The standard values and repair limit for TESTING AND ADJUSTING are described
in “Standard Value Table”.
40 Troubleshooting
This section describes troubleshooting of failure part and its remedy method on the occurrence of the failure.
Descriptions of troubleshooting are sorted by failure mode.

S.V 29/12/24