Komatsu D375A-6R Bulldozer Shop Manual SEN05214-17 PDF

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Komatsu D375A-6R Bulldozer Shop Manual SEN05214-17 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D375A-6R Bulldozer Shop Manual SEN05214-17 – PDF DOWNLOAD 

Language : English
Pages : 1798
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D375A-6R Bulldozer Shop Manual SEN05214-17 – PDF DOWNLOAD 

SERIAL NUMBERS 65001 and up

COVER 1
00 Index and Foreword 3
Table of contents 4
Table of contents 4
Foreword and general information 17
Safety notice 17
How to read the shop manual 22
Explanation of terms for maintenance standard 24
Handling of electric equipment and hydraulic components 26
Handling of connectors newly used for engines 35
How to read electric wire code 38
Precautions when carrying out work 41
Method of disassembling and connecting push-pull type coupler 44
Standard tightening torque table 47
List of Abbreviation 51
Conversion table 55
01 Specification 61
Specification and technical data 63
Specification drawing 63
Specifications 64
Weight table 69
Table of fuel, coolant and lubricants 71
10 Structure and function 73
Engine and cooling system 76
Cooling system 76
Cooling fan pump 79
Cooling fan motor 100
Power train 106
Power train 106
Overall drawing of power train unit 108
Power train hydraulic equipment arrangement drawing 110
Damper and universal joint 112
Torque converter and PTO 114
Torque converter control valve 120
Main relief valve and torque converter relief valve 122
Lockup clutch ECMV and stator clutch ECMV 124
Scavenging pump 129
Transmission control 130
PCCS lever 132
Transmission 136
Transmission ECMV 150
Transmission lubrication relief valve 155
Steering and brake control 156
Transfer unit, bevel gear shaft and steering 158
Steering control valve 164
Steering clutch ECMV and Steering brake ECMV 166
Parking brake valve 174
Sudden stop prevention valve 175
Final drive 177
Undercarriage and frame 182
Track frame 182
Idler cushion 184
Track roller bogie 185
Main frame 186
Suspension 188
Hydraulic system 191
Work equipment hydraulic piping diagram 191
PPC control piping diagram 195
Work equipment control 196
Hydraulic tank 198
Accumulator 200
PPC lock valve 201
PPC valve 202
Piston valve 214
Quick drop valve 215
Pin puller switch 217
Pin puller solenoid valve 218
Blade control lever (only for the machine with dual tilt specification) 220
Work equipment pump 222
Control valve 234
Self-pressure reducing valve 259
Work equipment 266
Cylinder stay 266
Cab 267
Cab mount 267
Cab 268
Electrical system 270
Engine control 270
Engine control system 271
CRI engine control system 280
Monitor system 282
Machine monitor 284
Lamp system 302
Engine preheat (electrical intake air heater) control 303
Palm command control system 304
Sensor 307
Vehicle health monitoring system (VHMS) 313
ORBCOMM system 319
Pre-lubrication system 322
20 Standard value table 327
Standard service value table 329
Standard value table for engine 329
Standard value table for machine 330
30 Testing and adjusting 339
Tools for testing, adjusting and troubleshooting 342
Diagnosis equipment list 342
Engine and cooling system 344
Testing engine speed 344
Testing intake air pressure (boost pressure) 347
Testing exhaust temperature 349
Testing exhaust gas color 352
Adjusting valve clearance 354
Measuring compression pressure 356
Testing blow-by pressure 359
Testing engine oil pressure 361
Handling of fuel system devices 362
Releasing residual pressure from fuel system 363
Testing fuel pressure 364
Handling of reduced cylinder mode operation 365
Handling of no injection cranking operation 366
Testing leakage from pressure limiter and return rate from injector 367
Bleeding air from fuel circuit 370
Testing fuel circuit for leakage 372
Replacing and adjusting alternator and air conditioner compressor belt 373
Measuring fan speed 374
Testing fan circuit oil pressure 375
Bleeding air from fan pump 376
Adjusting fuel control dial and decelerator pedal 377
Power train 380
Testing power train oil pressure 380
Adjusting transmission output speed sensor 394
Simple test procedure for brake performance 395
Adjusting brake pedal and parking brake lever 396
Adjusting position of pccs lever console 399
Emergency escape method when there is failure in power train 400
Undercarriage and frame 402
Inspecting wear of sprocket 402
Testing and adjusting track shoe tension 403
Hydraulic system 404
Testing and adjusting work equipment oil pressure 404
Testing control circuit main pressure 407
Testing PPC valve output pressure 408
Adjusting play of PPC valve 410
Testing output pressure of ripper pin-puller solenoid valve 411
Checking location of cause of hydraulic drift of blade and ripper 412
Testing leakage inside work equipment cylinder 413
Releasing remaining pressure in work equipment cylinders 414
Bleeding air from work equipment cylinders 415
Adjusting ripper lever position 416
Work equipment 418
Adjusting work equipment lock lever 418
Adjusting blade 419
Cab and its attachments 422
Testing and adjusting operator’s cab 422
Electrical system 428
Special functions of machine monitor (EMMS) 428
Handling of voltage circuit of engine controller 486
Adjustment method when controller has been replaced 487
Preparation work for troubleshooting for electrical equipment system 491
Inspection procedure of diode 495
Handling of optional devices 496
Request for opening ORBCOMM terminal 497
Initialization procedures for VHMS controller 499
Using method of KOMTRAX functions of ORBCOMM terminal 513
Precautions for replacing VHMS controller 516
Pm Clinic 522
Pm Clinic service 522
40 Troubleshooting 533
General information on troubleshooting 542
Points to remember when troubleshooting 542
Sequence of events in troubleshooting 543
Checks before troubleshooting 544
Classification and procedures for troubleshooting 569
Failure codes table 572
Classification and procedures for troubleshooting numbers 582
Information in troubleshooting table 584
Troubleshooting method for disconnecting wiring harness of pressure sensor system 586
Connection table for connector pin numbers 589
T-branch box and T-branch adapter table 625
Connector list and layout 628
Fuse locations table 642
Troubleshooting by failurecode 646
Failure code [1380MW] Lock up clutch: Slip 646
Failure code [1500L0] Transmission clutch: Abnormal 647
Failure code [15E0MW] Transmission clutch: Slip 648
Failure code [15SAL1] Forward clutch: Fill high 650
Failure code [15SALH] Forward clutch: Fill Low 652
Failure code [15SBL1] Reverse clutch: Fill high 654
Failure code [15SBLH] Reverse clutch: Fill Low 656
Failure code [15SEL1] Speed 1st clutch: Fill high 658
Failure code [15SELH] Speed 1st clutch: Fill Low 660
Failure code [15SFL1] Speed 2nd clutch: Fill high 662
Failure code [15SFLH] Speed 2nd clutch: Fill Low 664
Failure code [15SGL1] Speed 3rd clutch: Fill high 666
Failure code [15SGLH] Speed 3rd clutch: Fill Low 668
Failure code [15SJL1] L/U: Fill high 670
Failure code [15SJLH] L/U: Fill low 672
Failure code [1800MW] P/T clutch: Slip 674
Failure code [2201L1] Right clutch: Fill high 676
Failure code [2201LH] Right clutch: Fill low 678
Failure code [2202L1] Left clutch: Fill high 680
Failure code [2202LH] Left clutch: Fill low 682
Failure code [2300NR] Brake Themal Load Abnormality 684
Failure code [2301L1] Right brake: Fill high 686
Failure code [2301LH] Right brake: Fill low 688
Failure code [2301NR] Steering Brake RH Themal Load Abnormality 690
Failure code [2302L1] Left brake: Fill high 692
Failure code [2302LH] Left brake: Fill low 694
Failure code [2302NR] Steering Brake LH Themal Load Abnormality 696
Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection 698
Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit 700
Failure code [AA10NX] Air Cleaner Clogging 702
Failure code [AB00MA] Battery Charge Abnormal 704
Failure code [B@BAZG] Eng Oil Press Low 705
Failure code [B@BAZK] Eng Oil Level Low 706
Failure code [B@BCNS] Eng Water Overheat 707
Failure code [B@BCZK] Eng Water Level Low 708
Failure code [B@CENS] T/C Oil Overheat 709
Failure code [B@HANS] Hyd Oil Overheat 710
Failure code [B@HAZK] Hyd Oil Level Low 711
Failure code [CA111] ECM Critical Internal Failure 712
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 714
Failure code [CA122] Chg Air Press Sensor High Error 716
Failure code [CA123] Chg Air Press Sensor Low Error 718
Failure code [CA131] Throttle Sensor High Error 720
Failure code [CA132] Throttle Sensor Low Error 722
Failure code [CA135] Eng Oil Press Sensor High Error 724
Failure code [CA141] Eng Oil Press Sensor Low Error 726
Failure code [CA144] Coolant Temp Sens High Error 728
Failure code [CA145] Coolant Temp Sens Low Error 730
Failure code [CA153] Chg Air Temp Sensor High Error 732
Failure code [CA154] Chg Air Temp Sensor Low Error 734
Failure code [CA187] Sens Supply 2 Volt Low Error 736
Failure code [CA212] Eng Oil Temp Sensor High Error 738
Failure code [CA213] Eng Oil Temp Sensor Low Error 740
Failure code [CA221] Ambient Press Sens High Error 742
Failure code [CA222] Ambient Press Sens Low Error 744
Failure code [CA227] Sens Supply 2 Volt High Error 746
Failure code [CA234] Eng Overspeed 747
Failure code [CA238] Ne Speed Sens Supply Volt Error 748
Failure code [CA263] Fuel Temp Sensor High Error 750
Failure code [CA265] Fuel Temp Sensor Low Error 752
Failure code [CA271] IMV/PCV1 Short Error 754
Failure code [CA272] IMV/PCV1 Open Error 755
Failure code [CA273] PCV2 Short Error 756
Failure code [CA274] PCV2 Open Error 757
Failure code [CA322] Inj #1 (L#1) Open/Short Error 758
Failure code [CA323] Inj #5 (L#5) Open/Short Error 760
Failure code [CA324] Inj #3 (L#3) Open/Short Error 762
Failure code [CA325] Inj #6 (L#6) Open/Short Error 764
Failure code [CA331] Inj #2 (L#2) Open/Short Error 766
Failure code [CA332] Inj #4 (L#4) Open/Short Error 768
Failure code [CA342] Calibration Code Incompatibility 770
Failure code [CA351] Injectors Drive Circuit Error 771
Failure code [CA352] Sens Supply 1 Volt Low Error 772
Failure code [CA386] Sens Supply 1 Volt High Error 774
Failure code [CA441] Battery Voltage Low Error 775
Failure code [CA442] Battery Voltage High Error 776
Failure code [CA449] Rail Press Very High Error 777
Failure code [CA451] Rail Press Sensor High Error 778
Failure code [CA452] Rail Press Sensor Low Error 780
Failure code [CA553] Rail Press High Error 782
Failure code [CA554] Rail Press Sensor In Range Error 783
Failure code [CA559] Rail Press Low Error 784
Failure code [CA689] Eng Ne Speed Sensor Error 788
Failure code [CA731] Eng Bkup Speed Sens Phase Error 790
Failure code [CA757] All Continuous Data Lost Error 791
Failure code [CA778] Eng Bkup Speed Sensor Error 792
Failure code [CA1633] KOMNET Datalink Timeout Error 794
Failure code [CA2185] Throt Sens Sup Volt High Error 795
Failure code [CA2186] Throt Sens Sup Volt Low Error 796
Failure code [CA2249] Rail Press Very Low Error 797
Failure code [D110KB] Battery Relay: Drive Short Circuit 798
Failure code [D130KA] Neutral relay: Disconnection 800
Failure code [D130KB] Neutral relay: Short circuit 802
Failure code [D161KA] Back-up alarm releay: Disconnection 804
Failure code [D161KB] Back-up alarm releay: Short circuit 806
Failure code [D182KZ] Preheater Relay Abnormality 808
Failure code [D190KA] ACC signal relay: Disconnection 810
Failure code [D190KB] ACC signal relay: Short circuit 812
Failure code [D1EFKA] Pre lub motor relay: Disconnection 814
Failure code [D1EFKB] Pre lub motor relay: Short circuit 816
Failure code [DAFRKR] Monitor: Can communication lost (PT) 818
Failure code [dAFRKR] Monitor: CAN communication lost (WE) 819
Failure code [DAFRMC] CAN Discon (Monitor Detected) 820
Failure code [DB2RKR] ENG cont : Can communication lost (PT) 826
Failure code [dB2RKR] ENG controller: CAN communication lost (WE) 830
Failure code [DB90KT] WE controller: Abnormality in controller 831
Failure code [DB91KK] WE controller: Source voltage reduction 832
Failure code [DB92KK] WE controller: Output voltage reduction 834
Failure code [DB97KK] WE cont : Sensor voltage 5 V (2) reduction 836
Failure code [DB99KQ] WE controller: Type select signal 838
Failure code [DB9RKR] WE controller: Can communication lost (PT) 839
Failure code [DBB0KK] VHMS controller:Source voltage reduction 842
Failure code [DBB0KQ] VHMS connector connection abnormality 844
Failure code [DBB3KK] VHMS controller: Source voltage reduction 845
Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction 848
Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction 850
Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction 852
Failure code [DBBQKR] PT cont : Can communication lost (VHMS) 854
Failure code [DBE0KT] PT controller: Abnormality in controller 855
Failure code [DBE1KK] PT controller: Source voltage reduction 856
Failure code [DBE2KK] PT controller: Output voltage reduction 858
Failure code [DBE5KK] PT cont : Sensor voltage 5 V (1) reduction 860
Failure code [DBE6KK] PT cont : Sensor voltage 24V reduction 862
Failure code [DBE7KK] PT cont : Sensor voltage 5 V reduction 864
Failure code [DBE9KQ] PT controller: Type select signal 866
Failure code [DBERKR] PT controller: Can communication lost (WE) 867
Failure code [DD12KA] Shift up Sw: Disconnection 870
Failure code [DD12KB] Shift up Sw: Short circuit 872
Failure code [DD13KA] Shift down Sw: Disconnection 874
Failure code [DD13KB] Shift down Sw: Short circuit 876
Failure code [DD14KA] Parking lever Sw: Dissconnection 878
Failure code [DD14KB] Parking lever Sw: Short circuit 880
Failure code [DDB9L4] Reverse SW Signal disagreement 882
Failure code [DDE2KA] Pre lub oil press sw: Disconnection 884
Failure code [DDK3L4] Forward SW Signal disagreement 886
Failure code [DDK5KA] Shift switch disconnection 888
Failure code [DDK5KB] Shift switch short circuit 890
Failure code [DDN2LD] Blade tilt RH pressure SW abnormality 892
Failure code [DDN3LD] Blade tilt LH pressure SW abnormality 894
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection 896
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit 898
Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection 900
Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit 902
Failure code [DDNALD] Blade lift up pressure SW abnormality 904
Failure code [DDNBLD] Ripper lift up pressure SW abnormality 906
Failure code [DDNCLD] Ripper lift down pressure SW abnormality 908
Failure code [DDNDLD] Ripper tilt in pressure SW abnormality 910
Failure code [DDNELD] Ripper tilt back pressure SW abnormality 912
Failure code [DDNFLD] Blade lift down pressure SW abnormality 914
Failure code [DDNLKA] Weq lock Sw: Disconnection 916
Failure code [DDNLKB] Weq lock Sw: Short circuit 918
Failure code [DDT5KA] Neutral switch disconnection 920
Failure code [DDT5KB] Neutral switch short circuit 922
Failure code [DDT5KQ] Lever SPEC selection signal disagreement 924
Failure code [DDTSL1] S/C: Fill high 926
Failure code [DDTSLH] S/C: Fill low 928
Failure code [DGE5KX] Ambient temp sensor abnormality 930
Failure code [DGS1KX] Hyd oil temp: signal abnormal 932
Failure code [DGT1KA] T/C oil temp sensor: Abnormal 934
Failure code [DGT1KX] T/C oil temp sensor: Abnormal 936
Failure code [DGT5KA] F exhaust temp sensor disconnection 938
Failure code [DGT5KB] F exhaust temp sensor short circuit 940
Failure code [DGT6KA] R exhaust temp sensor disconnection 942
Failure code [DGT6KB] R exhaust temp sensor short circuit 944
Failure code [DH21KA] Weq pressure sensor: Disconnection 946
Failure code [DH21KB] Weq pressure sensor: Short circuit 948
Failure code [DHE5KB] ENG blow-by pressure sensor disconnection 950
Failure code [DHE5KY] ENG blow-by pressure sensor short circuit 952
Failure code [DHT3KX] T/M oil pressure sensor abnormality 954
Failure code [DHT5KA] T/C in-pressure sensor: Disconnection 956
Failure code [DHT5KB] T/C in-pressure sensor: Short circuit 958
Failure code [DHT7KA] T/C out-pressure sensor: Disconnection 960
Failure code [DHT7KB] T/C out-pressure sensor: Short circuit 962
Failure code [DK10KA] Fuel control Dial: Disconnection 964
Failure code [DK10KB] Fuel control Dial: Short circuit 966
Failure code [DK30KA] ST lever 1: Disconnection 968
Failure code [DK30KB] ST lever 1: Short circuit 970
Failure code [DK30KX] ST lever: Out of normal range 972
Failure code [DK30KZ] ST lever: Disconnection or short circuit 973
Failure code [DK30L8] ST lever: Signal mismatch 974
Failure code [DK31KA] ST lever 2: Disconnection 976
Failure code [DK31KB] ST lever 2: Short circuit 978
Failure code [DK40KA] Brake potentiometer: Disconnection 980
Failure code [DK40KB] Brake potentiometer: Short circuit 982
Failure code [DK55KX] FR lever: Out of normal range 984
Failure code [DK55KZ] FR lever: Disconnection or short circuit 985
Failure code [DK55L8] FR lever: Signal mismatch 986
Failure code [DK56KA] FR lever 1: Disconnection 988
Failure code [DK56KB] FR lever 1: Short circuit 990
Failure code [DK57KA] FR lever 2: Disconnection 992
Failure code [DK57KB] FR lever 2: Short circuit 994
Failure code [DK60KA] Acceleration sensor: Disconnection 996
Failure code [DK60KB] Acceleration sensor: Short circuit 998
Failure code [DKH1KA] Pitch angle sensor: Disconnection 1000
Failure code [DKH1KB] Pitch angle sensor: Short circuit 1002
Failure code [DLF1KA] T/C out-speed sensor: Disconnection 1004
Failure code [DLM3KA] Fan rev sensor: Disconnection 1006
Failure code [DLM3MB] Fan control: Decline 1008
Failure code [DLT3KA] T/M out-speed sensor: Disconnection 1009
Failure code [DLT3KB] T/M out-speed sensor: Abnormal 1010
Failure code [DW59KA] Blade dual selector SOL disconnection 1011
Failure code [DW59KB] Blade dual selector SOL short circuit 1012
Failure code [DW59KY] Blade dual selector SOL hot short 1014
Failure code [DW5AKA] Blade pitch selector SOL disconnection 1016
Failure code [DW5AKB] Blade pitch selector SOL short circuit 1017
Failure code [DW5AKY] Blade pitch selector SOL Short circuit 1018
Failure code [DW7BKA] Fan rev EPC: Disconnection 1020
Failure code [DW7BKB] Fan rev EPC: Short circuit 1021
Failure code [DWN3KA] Ssp solenoid: Disconnection 1022
Failure code [DWN3KB] Ssp solenoid: Short circuit 1024
Failure code [DWN3KY] SSP solenoid: Short circuit 1026
Failure code [DWN5KA] Fan pump solenoid 1: Disconnection 1028
Failure code [DWN5KB] Fan pump solenoid 1: Short circuit 1030
Failure code [DWN5KY] Fan pump solenoid 1: Short circuit 1032
Failure code [DWNCKA] Fan pump solenoid 2: Disconnection 1034
Failure code [DWNCKB] Fan pump solenoid 2: Short circuit 1036
Failure code [DWNCKY] Fan pump solenoid 2: Short circuit 1038
Failure code [DXH1KA] Lock-up ECMV: Disconnection 1040
Failure code [DXH1KB] Lock-up ECMV: Short circuit 1041
Failure code [DXH1KY] Lock-up ECMV: Short circuit 1042
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 1044
Failure code [DXH4KB] 1st clutch ECMV: Short circuit 1046
Failure code [DXH4KY] 1st clutch ECMV: Short circuit 1048
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 1050
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 1052
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit 1054
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 1056
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 1058
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit 1060
Failure code [DXH7KA] R clutch ECMV: Disconnection 1062
Failure code [DXH7KB] R clutch ECMV: Short circuit 1064
Failure code [DXH7KY] R clutch ECMV: Short circuit 1066
Failure code [DXH8KA] F clutch ECMV: Disconnection 1068
Failure code [DXH8KB] F clutch ECMV: Short circuit 1070
Failure code [DXH8KY] F clutch ECMV: Short circuit 1072
Failure code [DXH9KA] Right clutch ECMV: Disconnection 1074
Failure code [DXH9KB] Right clutch ECMV: Short circuit 1076
Failure code [DXH9KY] Right clutch ECMV: Short circuit 1078
Failure code [DXHAKA] Left clutch ECMV: Disconnection 1080
Failure code [DXHAKB] Left clutch ECMV: Short circuit 1082
Failure code [DXHAKY] Left clutch ECMV: Short circuit 1084
Failure code [DXHBKA] Right brake ECMV: Disconnection 1086
Failure code [DXHBKB] Right brake ECMV: Short circuit 1088
Failure code [DXHBKY] Right brake ECMV: Short circuit 1090
Failure code [DXHCKA] Left brake ECMV: Disconnection 1092
Failure code [DXHCKB] Left brake ECMV: Short circuit 1094
Failure code [DXHCKY] Left brake ECMV: Short circuit 1096
Failure code [DXJBKA] S/C ECMV: Disconnection 1098
Failure code [DXJBKB] S/C ECMV: Short circuit 1099
Failure code [DXJBKY] S/C ECMV: Short circuit 1100
Failure code [DY2HKA] Pre lub motor: Disconnection 1102
Failure code [F@BBZL] ENG blow-by pressure high level 1104
Failure code [F@BYNR] F exhaust temp high level (2) 1105
Failure code [F@BYNS] F exhaust temp high level (1) 1106
Failure code [F@BZNR] R exhaust temp high level (2) 1107
Failure code [F@BZNS] R exhaust temp high level (1) 1108
Troubleshooting of electrical system (E-mode) 1110
Information contained in troubleshooting table 1110
E-1 Engine does not start (starting motor does not turn) 1112
E-2 Preheater does not operate 1116
E-3 When starting switch is turned ON, machine monitor displays nothing 1120
E-4 When starting switch is turned ON (before starting engine), basic check item lights up 1124
E-5 Precaution item lights up while engine is running 1126
E-6 Emergency stop item lights up while engine is running 1128
E-7 Engine coolant temperature gauge does not indicate normally 1129
E-8 Fuel gauge does not indicate properly 1130
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally 1132
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally 1133
E-11 Contents of display by machine monitor are different from applicable machine 1134
E-12 Machine monitor does not display some items 1134
E-13 Function switch does not work 1134
E-14 Operation mode does not change 1135
E-15 Gearshift mode does not change 1135
E-16 Customize function does not operate normally 1136
E-17 Customize memory function does not operate normally 1136
E-18 Alarm buzzer does not sound or does not stop 1137
E-19 When starting switch is turned OFF, service meter is not displayed 1137
E-20 Machine monitor cannot be set in service mode 1137
E-21 The ripper pin puller cylinder does not operate 1138
E-22 Horn does not sound or does not stop 1140
E-23 Back-up alarm does not sound or does not stop 1142
E-24 Fan does not reverse 1144
E-25 The head lamp and rear lamp do not light up 1145
E-26 Windshield wiper does not operate 1154
E-27 Window washer does not operate 1162
E-28 Electric priming pump does not operate or does not stop automatically 1170
E-29 Orbcomm terminal does not operate normally (Data are not transmitted) 1172
E-30 Gear cannot be shifted 1174
Troubleshooting of hydraulic and mechanical system (H-mode) 1176
Information in troubleshooting table 1176
List of Failure Modes and Causes 1178
H-1 Machine lacks power(or drawbar pull) 1180
H-2 Machine cannot travel (at 2nd or 3rd each speed) 1182
H-3 Machine cannot travel at any gear speeds 1183
H-4 Machine travels only in one direction, forward or reverse 1185
H-5 Large time lag at gear shifting or directional change 1186
H-6 Machine connot turn 1187
H-7 Machine turns only to one side 1188
H-8 Machine overruns at turnning 1189
H-9 Brake does not work 1190
H-10 Torque converter does not lock up 1191
H-11 Power train oil overheats 1192
H-12 All work equipment operates too slow or lacks power 1193
H-13 All work equipment does not operate 1194
H-14 Blade lift cylinder speed is too slow or lacks power 1195
H-15 Blade tilt cylinder speed is too slow or lacks power 1196
H-16 Ripper lift cylinder speed is too slow or lacks power 1197
H-17 Ripper tilt cylinder speed is too slow or lacks power 1198
H-18 Excessive hydraulic drift of blade lift cylinder 1199
H-19 Excessive hydraulic drift of blade tilt cylinder 1200
H-20 Excessive hydraulic drift of ripper lift cylinder 1201
H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) 1202
H-22 Blade pitch does not work (machine with dual tilt specification) 1203
H-23 Abnormal noise from around work equipment pump 1204
H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats) 1205
Troubleshooting of engine (S-mode) 1206
Method of using troubleshooting chart 1206
S-1 Engine does not start easily 1210
S-2 Engine does not start 1211
S-3 Engine does not rev up smoothly (response-up is poor) 1214
S-4 Engine stops during operation 1215
S-5 Engine does not rotate smoothly (hunting) 1216
S-6 Engine lacks power (or output shortage) 1217
S-7 Exhaust smoke is black (Incomplete combustion) 1218
S-8 Oil is consumption is excessive(or exhaust smoke is blue) 1219
S-9 Engine oil becomes contaminated quickly 1220
S-10 Fuel consumption is excessive 1221
S-11 Oil mixes into coolant(coolant blows back or is reduced) 1222
S-12 Engine pressure monitor lights up (drop in engine oil pressure) 1223
S-13 Oil level rises (Coolant or fuel mixes into oil) 1224
S-14 Coolant temperature rises too high (overheating) 1225
S-15 Abnormal noise is heard 1226
S-16 Vibration is excessive 1227
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) 1228
50 Disassembly and assembly 1231
General information on disassembly and assembly 1234
How to read this manual 1234
Coating materials list 1236
Special tool list 1239
Sketches of special tools 1247
Engine and cooling system 1255
Removal and installation of fuel supply pump assembly 1255
Removal and installation of fuel injector assembly 1260
Removal and installation of cylinder head assembly 1265
Removal and installation of radiator guard assembly 1280
Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler) 1285
Removal and installation of radiator 1290
Removal and installation of hydraulic oil cooler 1292
Removal and installation of aftercooler 1293
Removal and installation of engine assembly 1294
Removal and installation of engine hood assembly 1301
Removal and installation of engine front seal 1304
Removal and installation of engine rear seal 1306
Removal and installation of fan drive assembly 1310
Removal and installation of fan motor assembly 1312
Removal and installation of fuel tank assembly 1314
Power train 1316
Removal and installation of damper assembly 1316
Disassembly and assembly of damper assembly 1320
Removal and installation of power train unit assembly 1323
Disconnection and connection of power train unit assembly 1329
Disassembly and assembly of PTO assembly 1338
Disassembly and assembly of torque converter assembly 1344
Disassembly and assembly of TORQFLOW transmission assembly 1353
Disassembly and assembly of steering case assembly 1380
Removal and installation of power train pump and lubrication pump assembly 1396
Removal and installation of scavenging pump assembly 1397
Removal and installation of final drive assembly 1398
Disassembly and assembly of final drive assembly 1400
Undercarriage and frame 1413
Removal and installation of track frame assembly 1413
Removal and installation of idler assembly 1418
Disassembly and assembly of idler assembly 1419
Removal and installation of recoil spring assembly 1423
Disassembly and assembly of recoil spring assembly 1438
Removal and installation of track roller assembly 1440
Disassembly and assembly of track roller assembly 1443
Removal and installation of carrier roller assembly 1446
Disassembly and assembly of carrier roller assembly 1447
Removal and installation of bogie assembly 1451
Disassembly and assembly of bogie assembly 1456
Removal and installation of first bogie assembly 1458
Separation and connection of track shoe assembly 1463
Overall disassembly and assembly of track shoe 1467
Link press press-fitting jig dimensions 1484
Disassembly and assembly of one link assembly in the field 1485
Disassembly and assembly of master link 1490
Removal and installation of pivot shaft assembly 1494
Removal and installation of equalizer bar 1495
Disassembly and assembly of equalizer bar bushing 1499
Removal and installation of segment tooth 1501
Hydraulic system 1502
Removal and installation of hydraulic tank assembly 1502
Removal and installation of work equipment pump assembly 1505
Removal and installation of fan pump assembly 1509
Removal and installation of control valve assembly 1511
Disassembly and assembly of control valve assembly 1513
Disassembly and assembly of blade PPC valve assembly 1518
Disassembly and assembly of ripper PPC valve assembly 1521
Disassembly and assembly of hydraulic cylinder assembly 1523
Disassembly and assembly of ripper pin puller cylinder assembly 1531
Work equipment 1534
Removal and installation of blade assembly 1534
Removal and installation of blade lift cylinder assembly 1536
Disassembly and assembly of blade assembly 1546
Disassembly and assembly of giant ripper assembly 1550
Cab and its attachments 1553
Removal and installation of ROPS guard 1553
Removal and installation of operator’s cab assembly 1554
Removal and installation of floor frame assembly 1558
Removal and installation of air conditioner unit assembly 1562
Electrical system 1569
Removal and installation of transmission controller assembly and steering controller assembly 1569
Removal and installation of engine controller assembly 1570
Removal and installation of VHMS controller assembly 1572
Removal and installation of machine monitor assembly 1573
60 Maintenance Standard 1575
Engine and cooling system 1577
Engine mount 1577
Cooling fan pump 1579
Cooling fan motor 1586
Power train 1588
Power train unit 1588
Damper and universal joint 1590
Torque converter and PTO 1593
Main relief valve and torque converter relief valve 1596
Lockup clutch ECMV and stator clutch ECMV 1597
Scavenging pump 1598
Transmission control 1599
Transmission 1600
Transmission lubricating oil relief valve 1605
Power train and lubrication pump 1606
Transfer, bevel gear shaft and steering unit 1608
Steering control valve 1614
Steering clutch ECMV and steering brake ECMV 1615
Parking brake valve 1616
Final drive 1617
Sprocket 1620
Undercarriage and frame 1622
Track frame 1622
Idler cushion 1624
Idler 1626
Track roller 1628
Carrier roller 1630
Track roller bogie 1631
Track shoe 1632
Main frame 1636
Suspension 1638
Hydraulic system 1642
PPC valve 1642
Hydraulic cylinder 1648
Quick drop valve 1651
Work equipment pump 1652
Control valve 1655
Self-pressure reducing valve 1668
Work equipment 1671
Cylinder stay 1671
Blade 1672
Cutting edge and end bit 1676
Ripper 1678
80 Appendix 1681
Air conditioner 1683
Precautions for refrigerant 1683
Air conditioner component 1684
Configuration and function of refrigeration cycle 1686
Outline of refrigeration cycle 1687
Air conditioner unit 1690
Blower unit 1694
FRESH/RECIRC air changeover damper 1695
Compressor 1696
Condenser 1697
Receiver drier 1698
Air conditioner control panel 1700
Procedure for testing and troubleshooting 1702
Circuit diagram and arrangement of connector pins 1704
System diagram 1706
Parts and connectors layout 1708
Testing temperature control 1712
Testing FRESH/RECIC air changeover 1713
Testing relay 1714
Troubleshooting chart 1 1716
Troubleshooting chart 2 1718
Information in troubleshooting table 1720
Troubleshooting for power supply system (Air conditioner does not operate) 1722
Troubleshooting for compressor system (Air is not cooled) 1724
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) 1728
Troubleshooting for temperature control 1734
Troubleshooting for FRESH/RECIRC air changeover 1736
Troubleshooting with gauge pressure 1738
Connection of service tool 1740
Precautions for disconnecting and connecting 1742
Handling of compressor oil 1744
90 Diagrams and Drawings 1747
Hydraulic diagrams and drawings 1749
Symbols used in hydraulic circuit diagrams 1749
Power train hydraulic circuit diagram 1751
Hydraulic circuit diagram 1753
Electrical diagrams and drawings 1757
Symbols used in electrical circuit diagrams 1757
Electrical circuit diagram 1761
Index 1789

DESCRIPTION:

Komatsu D375A-6R Bulldozer Shop Manual SEN05214-17 – PDF DOWNLOAD 

SERIAL NUMBERS 65001 and up

How to read the shop manual 
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For
ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section contains the index, foreword and safety and basic information.If any revision is made, the
LIST OF REVISED PAGES will be added.
01. Specification
This section explains the specifications of the machine.
10. Structure and function
This section explains the structure and function of each component.It serves not only to give an understanding
for the structure of each component, but also serves as reference material for troubleshooting.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting,
and troubleshooting. This standard value table is used to check the standard values in testing and adjusting
and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, as well as
the adjusting method of each part.The standard values and judgment criteria for “Testing and adjusting”
are explained in standard value table.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided
by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in the
Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and assembling
each component, as well as precautions for them.In addition, tightening torque, and quantity and
weight of coating material, oil, grease, and coolant necessary for the work are also explained.
60. Maintenance standard
This section gives maintenance standard values of each component. The maintenance standard sub-section
explains the criteria and remedies for disassembly and service.
80. Appendix
This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not
classifiable in other sections.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of remanufacturing and repairing engine and replacing parts.

S.V 29/12/24