Komatsu D375A-6 Bulldozer (60001 and up) Service Repair Shop Manual - SEN05006-09

This complete service repair workshop manual PDF download for the D375A-6 Komatsu Bulldozer (SN: 60001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Machine Model : D375A-6
Serial Numbers : 60001 and up


TABLE OF CONTENTS :

00. Index and foreword
01. Specification
10. Structure and function
20. Standard value table
30. Testing and adjusting
40. Troubleshooting
50. Disassembly and assembly
60. Maintenance standard
80. Appendix
90. Diagrams and drawings


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEN05006-09
Total Pages : 1735


This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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00 Index and Foreword
Table of contents
Forword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic components
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out work
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
List of Abbreviation
Conversion table

01 Specification
Specification and technical data
Specification drawing
Specifications
Weight table
Table of fuel, coolant and lubricants

10 Structure and function
Engine and cooling system
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Power train
Overall drawing of power train unit
Power train hydraulic equipment arrangement drawing
Damper and universal joint
Torque converter and PTO
Torque converter control valve
Main relief valve and torque converter relief valve
Lockup clutch ECMV and stator clutch ECMV
Scavenging pump
Transmission control
PCCS lever
Transmission
Transmission ECMV
Transmission lubricating oil relief valve
Steering and brake control
Transfer unit, bevel gear shaft and steering
Steering control valve
Steering clutch ECMV and Steering brake ECMV
Parking brake valve
Sudden stop prevention valve
Final drive
Undercarriage and frame
Track frame
Idler cushion
Track roller bogie
Main frame
Suspension
Hydraulic system
Work equipment hydraulic piping diagram
PPC control piping diagram
Work equipment control
Hydraulic tank
Accumulator
PPC lock valve
PPC valve
Piston valve
Quick drop valve
Pin puller switch
Pin puller solenoid valve
Blade control lever (only for the machine with dual tilt specification)
Work equipment pump
Control valve
Self-pressure reducing valve
Work equipment
Cylinder stay
Cab and its attachments
Cab mount
Cab
Electrical system
Engine control
Engine control system
CRI engine control system
Monitor system
Machine monitor
Lamp system
Engine preheat (electrical intake air heater) control
Palm command control system
Sensor
Vehicle health monitoring system (VHMS)
ORBCOMM system

20 Standard value table
Standard service value table
Standard value table for engine
Standard value table for machine

30 Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Tools for testing, adjusting, and troubleshooting
Engine and cooling system
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Testing blow-by pressure
Testing engine oil pressure
Testing EGR valve drive oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Testing leakage from pressure limiter and return rate from injector
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Replacing and adjusting alternator and air conditioner compressor belt
Measuring fan speed
Testing fan circuit oil pressure
Bleeding air from fan pump
Adjusting fuel control dial and decelerator pedal
Power train
Testing power train oil pressure
Adjusting transmission output speed sensor
Simple test procedure for brake performance
Adjusting brake pedal and parking brake lever
Adjusting position of pccs lever console
Emergency escape method when there is failure in power train
Undercarriage and frame
Inspecting wear of sprocket
Testing and adjusting track shoe tension
Hydraulic system
Measuring and adjusting work equipment oil pressure
Testing control circuit main pressure
Testing PPC valve output pressure
Adjusting play of PPC valve
Testing output pressure of ripper pin-puller solenoid valve
Checking location of cause of hydraulic drift of blade and ripper
Testing leakage inside work equipment cylinder
Releasing remaining pressure in work equipment cylinders
Bleeding air from work equipment cylinders
Adjusting ripper lever position
Work equipment
Adjusting work equipment lock lever
Adjusting blade
Cab and its attachments
Testing and adjusting operator's cab
Electrial system
Special functions of machine monitor (EMMS)
Handling of voltage circuit of engine controller
Adjustment method when controller has been replaced
Preparation work for troubleshooting of electrical system
Inspection procedure of diode
Handling of optional devices
Request for opening ORBCOMM terminal
Initialization procedures for VHMS controller
Using method of KOMTRAX functions of ORBCOMM terminal
Precautions for replacing VHMS controller
Pm Clinic service
Pm Clinic service

40 Troubleshooting
General Information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Failure codes table
Phenomena and troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Connection table for connector pin numbers
Connectors table and arrangement drawing
T-branch box and T-branch adapter table
Fuse locations table
Troubleshooting by failure code
Failure code [1380MW] Lock up clutch: Slip
Failure code [1500L0] Transmission clutch: Abnormal
Failure code [15E0MW] Transmission clutch: Slip
Failure code [15SAL1] Forward clutch: Fill high
Failure code [15SALH] Forward clutch: Fill Low
Failure code [15SBL1] Reverse clutch: Fill high
Failure code [15SBLH] Reverse clutch: Fill Low
Failure code [15SEL1] Speed 1st clutch: Fill high
Failure code [15SELH] Speed 1st clutch: Fill Low
Failure code [15SFL1] Speed 2nd clutch: Fill high
Failure code [15SFLH] Speed 2nd clutch: Fill Low
Failure code [15SGL1] Speed 3rd clutch: Fill high
Failure code [15SGLH] Speed 3rd clutch: Fill Low
Failure code [15SJL1] L/U: Fill high
Failure code [15SJLH] L/U: Fill low
Failure code [1800MW] P/T clutch: Slip
Failure code [2201L1] Right clutch: Fill high
Failure code [2201LH] Right clutch: Fill low
Failure code [2202L1] Left clutch: Fill high
Failure code [2202LH] Left clutch: Fill low
Failure code [2300NR] Brake Themal Load Abnormality
Failure code [2301L1] Right brake: Fill high
Failure code [2301LH] Right brake: Fill low
Failure code [2301NR] Steering Brake RH Themal Load Abnormality
Failure code [2302L1] Left brake: Fill high
Failure code [2302LH] Left brake: Fill low
Failure code [2302NR] Steering Brake LH Themal Load Abnormality
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit
Failure code [AA10NX] Air Cleaner Clogging
Failure code [AB00MA] Battery Charge Abnormal
Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BAZK] Eng Oil Level Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@BCZK] Eng Water Level Low
Failure code [B@CENS] T/C Oil Overheat
Failure code [B@HANS] Hyd Oil Overheat
Failure code [B@HAZK] Hyd Oil Level Low
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA135] Eng Oil Press Sensor High Error
Failure code [CA141] Eng Oil Press Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA212] Eng Oil Temp Sensor High Error
Failure code [CA213] Eng Oil Temp Sensor Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA263] Fuel Temp Sensor High Error
Failure code [CA265] Fuel Temp Sensor Low Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA273] PCV2 Short Error
Failure code [CA274] PCV2 Open Error
Failure code [CA322] Inj #1 (L#1) Open/Short Error
Failure code [CA323] Inj #5 (L#5) Open/Short Error
Failure code [CA324] Inj #3 (L#3) Open/Short Error
Failure code [CA325] Inj #6 (L#6) Open/Short Error
Failure code [CA331] Inj #2 (L#2) Open/Short Error
Failure code [CA332] Inj #4 (L#4) Open/Short Error
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA553] Rail Press High Error
Failure code [CA554] Rail Press Sensor In Range Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1228] EGR Valve Servo Error 1
Failure code [CA1625] EGR Valve Servo Error 2
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2271] EGR Valve Pos Sens High Error
Failure code [CA2272] EGR Valve Pos Sens Low Error
Failure code [CA2351] EGR Valve Sol Current High Error
Failure code [CA2352] EGR Valve Sol Current Low Error
Failure code [D110KB] Battery Relay: Drive Short Circuit
Failure code [D130KA] Neutral relay: Disconnection
Failure code [D130KB] Neutral relay: Short circuit
Failure code [D161KA] Back-up alarm releay: Disconnection
Failure code [D161KB] Back-up alarm releay: Short circuit
Failure code [D182KZ] Preheater Relay Abnormality
Failure code [D190KA] ACC signal relay: Disconnection
Failure code [D190KB] ACC signal relay: Short circuit
Failure code [D1EFKA] Pre lub. motor relay: Disconnection
Failure code [D1EFKB] Pre lub. motor relay: Short circuit
Failure code [DAFRKR] Monitor: Can communication lost (PT)
Failure code [dAFRKR] Monitor: CAN communication lost (WE)
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DB2RKR] ENG cont.: Can communication lost (PT)
Failure code [dB2RKR] ENG controller: CAN communication lost (WE)
Failure code [DB90KT] WE controller: Abnormality in controller
Failure code [DB91KK] WE controller: Source voltage reduction
Failure code [DB92KK] WE controller: Output voltage reduction
Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction
Failure code [DB99KQ] WE controller: Type select signal
Failure code [DB9RKR] WE controller: Can communication lost (PT)
Failure code [DBB0KK] VHMS controller:Source voltage reduction
Failure code [DBB0KQ] VHMS connector connection abnormality
Failure code [DBB3KK] VHMS controller: Source voltage reduction
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction
Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)
Failure code [DBE0KT] PT controller: Abnormality in controller
Failure code [DBE1KK] PT controller: Source voltage reduction
Failure code [DBE2KK] PT controller: Output voltage reduction
Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction
Failure code [DBE6KK] PT cont.: Sensor voltage 24 V reduction
Failure code [DBE7KK] PT cont.: Sensor voltage 5 V (2) reduction
Failure code [DBE9KQ] PT controller: Type select signal
Failure code [DBERKR] PT controller: Can communication lost (WE)
Failure code [DD12KA] Shift up Sw: Disconnection
Failure code [DD12KB] Shift up Sw: Short circuit
Failure code [DD13KA] Shift down Sw: Disconnection
Failure code [DD13KB] Shift down Sw: Short circuit
Failure code [DD14KA] Parking lever Sw: Dissconnection
Failure code [DD14KB] Parking lever Sw: Short circuit
Failure code [DDB9L4] Reverse SW Signal disagreement
Failure code [DDE2KA] Pre lub. oil press sw: Disconnection
Failure code [DDK3L4] Forward SW Signal disagreement
Failure code [DDK5KA] Shift switch disconnection
Failure code [DDK5KB] Shift switch short circuit
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit
Failure code [DDNALD] Blade lift up pressure SW abnormality
Failure code [DDNBLD] Ripper lift up pressure SW abnormality
Failure code [DDNCLD] Ripper lift down pressure SW abnormality
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality
Failure code [DDNELD] Ripper tilt back pressure SW abnormality
Failure code [DDNFLD] Blade lift down pressure SW abnormality
Failure code [DDNLKA] Weq lock Sw: Disconnection
Failure code [DDNLKB] Weq lock Sw: Short circuit
Failure code [DDT5KA] Neutral switch disconnection
Failure code [DDT5KB] Neutral switch short circuit
Failure code [DDT5KQ] Lever SPEC selection signal disagreement
Failure code [DDTSL1] S/C: Fill high
Failure code [DDTSLH] S/C: Fill low
Failure code [DGE5KX] Ambient temp sensor abnormality
Failure code [DGS1KX] Hyd oil temp: signal abnormal
Failure code [DGT1KA] T/C oil temp sensor: Abnormal
Failure code [DGT1KX] T/C oil temp sensor: Abnormal
Failure code [DGT5KA] F exhaust temp sensor disconnection
Failure code [DGT5KB] F exhaust temp sensor short circuit
Failure code [DGT6KA] R exhaust temp sensor disconnection
Failure code [DGT6KB] R exhaust temp sensor short circuit
Failure code [DH21KA] Weq pressure sensor: Disconnection
Failure code [DH21KB] Weq pressure sensor: Short circuit
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit
Failure code [DHT3KX] T/M oil pressure sensor abnormality
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit
Failure code [DK10KA] Fuel control Dial: Disconnection
Failure code [DK10KB] Fuel control Dial: Short circuit
Failure code [DK30KA] ST lever 1: Disconnection
Failure code [DK30KB] ST lever 1: Short circuit
Failure code [DK30KX] ST lever: Out of normal range
Failure code [DK30KZ] ST lever: Disconnection or short circuit
Failure code [DK30L8] ST lever: Signal mismatch
Failure code [DK31KA] ST lever 2: Disconnection
Failure code [DK31KB] ST lever 2: Short circuit
Failure code [DK40KA] Brake potentiometer: Disconnection
Failure code [DK40KB] Brake potentiometer: Short circuit
Failure code [DK55KX] FR lever: Out of normal range
Failure code [DK55KZ] FR lever: Disconnection or short circuit
Failure code [DK55L8] FR lever: Signal mismatch
Failure code [DK56KA] FR lever 1: Disconnection
Failure code [DK56KB] FR lever 1: Short circuit
Failure code [DK57KA] FR lever 2: Disconnection
Failure code [DK57KB] FR lever 2: Short circuit
Failure code [DK60KA] Acceleration sensor: Disconnection
Failure code [DK60KB] Acceleration sensor: Short circuit
Failure code [DKH1KA] Pitch angle sensor: Disconnection
Failure code [DKH1KB] Pitch angle sensor: Short circuit
Failure code [DLF1KA] T/C out-speed sensor: Disconnection
Failure code [DLM3KA] Fan rev. sensor: Disconnection
Failure code [DLM3MB] Fan control: Decline
Failure code [DLT3KA] T/M out-speed sensor: Disconnection
Failure code [DLT3KB] T/M out-speed sensor: Abnormal
Failure code [DW59KA] Blade dual selector SOL disconnection
Failure code [DW59KB] Blade dual selector SOL short circuit
Failure code [DW59KY] Blade dual selector SOL hot short
Failure code [DW5AKA] Blade pitch selector SOL disconnection
Failure code [DW5AKB] Blade pitch selector SOL short circuit
Failure code [DW5AKY] Blade pitch selector SOL Short circuit
Failure code [DW7BKA] Fan rev EPC: Disconnection
Failure code [DW7BKB] Fan rev EPC: Short circuit
Failure code [DWN3KA] Ssp solenoid: Disconnection
Failure code [DWN3KB] Ssp solenoid: Short circuit
Failure code [DWN3KY] SSP solenoid: Short circuit
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit
Failure code [DXH1KA] Lock-up ECMV: Disconnection
Failure code [DXH1KB] Lock-up ECMV: Short circuit
Failure code [DXH1KY] Lock-up ECMV: Short circuit
Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KY] 1st clutch ECMV: Short circuit
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit
Failure code [DXH7KA] R clutch ECMV: Disconnection
Failure code [DXH7KB] R clutch ECMV: Short circuit
Failure code [DXH7KY] R clutch ECMV: Short circuit
Failure code [DXH8KA] F clutch ECMV: Disconnection
Failure code [DXH8KB] F clutch ECMV: Short circuit
Failure code [DXH8KY] F clutch ECMV: Short circuit
Failure code [DXH9KA] Right clutch ECMV: Disconnection
Failure code [DXH9KB] Right clutch ECMV: Short circuit
Failure code [DXH9KY] Right clutch ECMV: Short circuit
Failure code [DXHAKA] Left clutch ECMV: Disconnection
Failure code [DXHAKB] Left clutch ECMV: Short circuit
Failure code [DXHAKY] Left clutch ECMV: Short circuit
Failure code [DXHBKA] Right brake ECMV: Disconnection
Failure code [DXHBKB] Right brake ECMV: Short circuit
Failure code [DXHBKY] Right brake ECMV: Short circuit
Failure code [DXHCKA] Left brake ECMV: Disconnection
Failure code [DXHCKB] Left brake ECMV: Short circuit
Failure code [DXHCKY] Left brake ECMV: Short circuit
Failure code [DXJBKA] S/C ECMV: Disconnection
Failure code [DXJBKB] S/C ECMV: Short circuit
Failure code [DXJBKY] S/C ECMV: Short circuit
Failure code [DY2HKA] Pre lub. motor: Disconnection
Failure code [F@BBZL] ENG blow-by pressure high level
Failure code [F@BYNR] F exhaust temp high level (2)
Failure code [F@BYNS] F exhaust temp high level (1)
Failure code [F@BZNR] R exhaust temp high level (2)
Failure code [F@BZNS] R exhaust temp high level (1)
Troubleshooting of electrical system (E-mode)
Information contained in troubleshooting table
E-1 Engine does not start (starting motor does not turn)
E-2 Preheater does not operate
E-3 When starting switch is turned ON, machine monitor displays nothing
E-4 When starting switch is turned ON (before starting engine), basic check item lights up
E-5 Precaution item lights up while engine is running
E-6 Emergency stop item lights up while engine is running
E-7 Engine coolant temperature gauge does not indicate normally
E-8 Fuel gauge does not indicate properly
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-11 Contents of display by machine monitor are different from applicable machine
E-12 Machine monitor does not display some items
E-13 Function switch does not work
E-14 Operation mode does not change
E-15 Gearshift mode does not change
E-16 Customize function does not operate normally
E-17 Customize memory function does not operate normally
E-18 Alarm buzzer does not sound or does not stop
E-19 When starting switch is turned OFF, service meter is not displayed
E-20 Machine monitor cannot be set in service mode
E-21 The ripper pin puller cylinder does not operate
E-22 Horn does not sound or does not stop
E-23 Back-up alarm does not sound or does not stop
E-24 Fan does not reverse
E-25 The head lamp and rear lamp do not light up
E-26 Windshield wiper does not operate
E-27 Window washer does not operate
E-28 Electric priming pump does not operate or does not stop automatically
E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
E-30 Gear cannot be shifted
Troubleshooting of hydraulic and mechanical system (H-mode)
Information in troubleshooting table
List of Failure Modes and Causes
H-1 Machine lacks power(or drawbar pull)
H-2 Machine cannot travel (at 2nd or 3rd each speed)
H-3 Machine cannot travel at any gear speeds
H-4 Machine travels only in one direction, forward or reverse
H-5 Large time lag at gear shifting or directional change
H-6 Machine connot turn
H-7 Machine turns only to one side
H-8 Machine overruns at turnning
H-9 Brake does not work
H-10 Torque converter does not lock up
H-11 Power train oil overheats
H-12 All work equipment operates too slow or lacks power
H-13 All work equipment does not operate
H-14 Blade lift cylinder speed is too slow or lacks power
H-15 Blade tilt cylinder speed is too slow or lacks power
H-16 Ripper lift cylinder speed is too slow or lacks power
H-17 Ripper tilt cylinder speed is too slow or lacks power
H-18 Excessive hydraulic drift of blade lift cylinder
H-19 Excessive hydraulic drift of blade tilt cylinder
H-20 Excessive hydraulic drift of ripper lift cylinder
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper)
H-22 Blade pitch does not work (machine with dual tilt specification)
H-23 Abnormal noise from around work equipment pump
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)
Troubleshooting of engine (S-mode)
Method of using troubleshooting chart
S-1 Engine does not start easily
S-2 Engine does not start
S-3 Engine does not rev up smoothly (response-up is poor)
S-4 Engine stops during operation
S-5 Engine does not rotate smoothly (hunting)
S-6 Engine lacks power (or output shortage)
S-7 Exhaust smoke is black (Incomplete combustion)
S-8 Oil is consumption is excessive(or exhaust smoke is blue)
S-9 Engine oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil mixes into coolant(coolant blows back or is reduced)
S-12 Engine pressure monitor lights up (drop in engine oil pressure)
S-13 Oil level rises (Coolant or fuel mixes into oil)
S-14 Coolant temperature rises too high (overheating)
S-15 Abnormal noise is heard
S-16 Vibration is excessive
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)

50 Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketches of special tools
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator guard assembly
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
Removal and installation of radiator
Removal and installation of hydraulic oil cooler
Removal and installation of aftercooler
Removal and installation of engine assembly
Removal and installation of engine hood assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of fan drive assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of damper assembly
Disassembly and assembly of damper assembly
Removal and installation of power train unit assembly
Disconnection and connection of power train unit assembly
Disassembly and assembly of PTO assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of TORQFLOW transmission assembly
Disassembly and assembly of steering case assembly
Removal and installation of power train pump and lubrication pump assembly
Removal and installation of scavenging pump assembly
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Removal and installation of track frame assembly
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of bogie assembly
Disassembly and assembly of bogie assembly
Removal and installation of first bogie assembly
Separation and connection of track shoe assembly
Overall disassembly and assembly of track shoe
Link press press-fitting jig dimensions
Disassembly and assembly of one link assembly in the field
Disassembly and assembly of master link
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar
Disassembly and assembly of equalizer bar bushing
Removal and installation of segment tooth
Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of work equipment pump assembly
Removal and installation of fan pump assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of blade PPC valve assembly
Disassembly and assembly of ripper PPC valve assembly
Disassembly and assembly of hydraulic cylinder assembly
Disassembly and assembly of ripper pin puller cylinder assembly
Work equipment
Removal and installation of blade assembly
Disassembly and assembly of blade assembly
Disassembly and assembly of giant ripper assembly
Cab and its attachments
Removal and installation of ROPS guard
Removal and installation of operator’s cab assembly
Removal and installation of floor frame assembly
Removal and installation of air conditioner unit assembly
Electrical system
Removal and installation of transmission controller assembly and steering controller assembly
Removal and installation of engine controller assembly
Removal and installation of VHMS controller assembly
Removal and installation of machine monitor assembly

60 Maintenance Standard
Engine and cooling system
Engine mount
Cooling fan pump
Cooling fan motor
Power train
Power train unit
Damper and universal joint
Torque converter and PTO
Main relief valve and torque converter relief valve
Lockup clutch ECMV and stator clutch ECMV
Scavenging pump
Transmission control
Transmission
Transmission lubricating oil relief valve
Power train and lubrication pump
Transfer, bevel gear shaft and steering unit
Steering control valve
Steering clutch ECMV and steering brake ECMV
Parking brake valve
Final drive
Sprocket
Undercarriage and frame
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Track roller bogie
Track shoe
Main frame
Suspension
Hydraulic system
PPC valve
Hydraulic cylinder
Quick drop valve
Work equipment pump
Control valve
Self-pressure reducing valve
Work equipment
Cylinder stay
Blade
Cutting edge and end bit
Ripper

80 Appendix
Air Conditioner
Caution about refrigerant
Air conditioner component
Configuration and function of refrigeration cycle
Outline of refrigeration cycle
Air conditioner unit
Blower unit
FRESH/RECIRC air changeover damper
Compressor
Condenser
Receiver drier
Air conditioner control panel
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Part and connector locations
Testing temperature control
Testing FRESH/RECIC air changeover
Testing relay
Troubleshooting chart 1
Troubleshooting chart 2
Information in troubleshooting table
Troubleshooting for power supply system (Air conditioner does not operate)
Troubleshooting for compressor system (Air is not cooled)
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for FRESH/RECIRC air changeover
Troubleshooting with gauge pressure
Connection of service tool
Precautions for disconnecting and connecting
Handling of compressor oil

90 Diagrams and Drawings
Hydraulic diagrams and drawings
Symbols used in hydrauric cirxuit diagrams
Power train hydraulic circuit diagram
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbol use in electric circuit diagram
Electrical circuit diagram

INDEX

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