Komatsu D375A-8 Bulldozer Shop Manual SEN06729-04 PDF

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Komatsu D375A-8 Bulldozer Shop Manual SEN06729-04 – PDF DOWNLOAD

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Komatsu D375A-8 Bulldozer Shop Manual SEN06729-04 – PDF DOWNLOAD 

Language : English
Pages : 3182
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D375A-8 Bulldozer Shop Manual SEN06729-04 – PDF DOWNLOAD 

SERIAL NUMBERS 80001 and up

Cover 1
00 Index and Foreword 3
Index 4
Abbreviation List 23
Foreword, Safety, Basic Information 26
How to Read the Shop Manual 26
Safety Notice for Operation 28
Precautions to Prevent Fire 36
Procedures If Fire Occurs 38
Precautions When You Discard Waste Materials 39
Precautions When You Handle Hydraulic Equipment 40
Precautions When You Disconnect and Connect Pipings 43
Precautions When You Handle Electrical Equipment 49
Precautions When You Handle Fuel System Equipment 51
Precautions When You Handle Intake System Equipment 52
Practical Use of KOMTRAX 53
Disconnect and Connect Push-Pull Type Coupler 54
How to Disconnect and Connect Type 1 Push-Pull Type Coupler 54
How to Disconnect and Connect Type 2 Push-Pull Type Coupler 55
How to Disconnect and Connect Type 3 Push-Pull Type Coupler 56
Precautions for Disconnection and Connection of Connectors 58
How to Disconnect and Connect Deutsch Connector 62
How to Disconnect and Connect Slide Lock Type Connector 63
How to Disconnect and Connect Connector with Lock to Pull 65
How to Disconnect and Connect Connector with Lock to Push 66
How to Disconnect and Connect Connector with Housing to Rotate 68
How to Read the Codes for Electric Cable 69
Explanation of Terms for Maintenance Standard 73
Standard Tightening Torque Table 76
Conversion Table 83
01 Specifications 89
Table of Contents 90
Specifications 91
Specification Drawing 91
Specification Drawing: D375A-8 91
Specifications 93
Specification: D375A-8 93
Weight Table 100
Weight Table: D375A-8 100
Fuel, Coolant, Lubricants (For North America) 103
How to Use Fuel, Coolant and Lubricants by Ambient Temperature 103
10 Structure and Function 105
Table of Contents 106
Boot-up System 109
System Operating Lamp System 109
System Diagram of System Operating Lamp System 109
Function of Operation Lamp System 109
Battery Disconnect Switch 111
Layout Drawing of Battery Disconnect Switch 111
Function of Battery Disconnect Switch 111
Battery Isolator 113
Layout Drawing of Battery Isolator 113
Function of Battery Isolator 113
Engine System 115
Layout Drawing of Engine System 115
Engine Control System 117
Layout Drawing of Engine Control System 117
System Diagram of Engine Control 118
Function of Engine Control System 118
Automatic Idle Stop System 119
System Diagram of Automatic Idle Stop System 119
Function of Automatic Idle Stop System 119
Component Parts of Engine System 122
Damper 122
VGT 123
EGR System 127
EGR Valve 129
EGR Cooler 131
KCCV System 132
KCCV Ventilator 134
KDPF 136
Fuel System 141
Fuel System Circuit Diagram 141
Function of Fuel System 142
Operation of Fuel System 142
CRI System 142
Cooling System 147
Layout Drawing of Cooling System 147
Specifications of Cooling System 148
Component Parts of Cooling System 149
Cooling Fan Pump 149
Cooling Fan Motor 169
Hydraulic Oil Cooler Bypass Valve 176
Control System 177
Layout Drawing of Control System 177
Machine Monitor System 178
System Diagram of Machine Monitor System 178
Function of Machine Monitor System 178
KOMTRAX Plus System 181
System Diagram of KOMTRAX Plus System 181
Function of KOMTRAX Plus System 181
Component Parts of Control System 183
Machine Monitor 183
KOMTRAX Terminal 198
KOMTRAX Plus Controller 200
Wireless LAN Unit 204
Power Train Controller 205
Work Equipment Controller 213
Engine Controller 217
Option Controller 229
Fuel Feed Pump 233
Fuel Feed Pump Switch 234
Hydraulic System 235
Layout Drawing of Hydraulic System 235
CLSS 236
Structure of CLSS 236
Function of CLSS 237
Component Parts of Hydraulic System 239
Hydraulic Tank 239
Work Equipment Pump 241
LS Valve 244
PTO, Transmission Lubrication Pump, and Power Train Pump 249
Control Valve 250
Power Train System 270
Layout Drawing of Power Train System 270
Operation of Power Train System 273
Transmission, Steering, and Brake Control 274
Layout Drawing of Transmission, Steering, and Brake Control System 274
Function of Transmission, Steering, and Brake Control System 275
Layout Drawing of Transmission, Steering, and Brake Control System 275
Function of Transmission, Steering, and Brake Control System 278
Palm Command Control System 279
Palm Command Control System Diagram 279
Centralized Pressure Pickup Port 283
Layout Drawing of Centralized Pressure Pickup Port 283
Function of Centralized Pressure Pickup Port 284
Component Parts of Power Train System 285
Universal Joint 285
Power Train Mount 286
Torque Converter and PTO 287
Torque Converter Control Valve 294
Lockup Clutch ECMV 295
Stator Clutch ECMV 298
Transmission 302
Transmission ECMV 314
Main Relief Valve and Torque Converter Relief Valve 320
Transmission Lubrication Relief Valve 322
Transfer and Bevel Pinion 323
Bevel Gear Shaft, Steering Clutch, and Brake 324
Final Drive 331
Scavenging Pump 334
Electric Steering Electric Lever 335
Work Equipment System 341
Work Equipment Control 341
Layout Drawing of Work Equipment Control 341
Function of Work Equipment Control 342
Layout Drawing of Front Work Equipment 343
Layout Drawing of Variable Giant Ripper 344
Layout Drawing of Variable Multi-Shank Ripper 345
Shoe Slip Control System 346
Function of Shoes Slip Control System 346
Component Parts of Work Equipment System 347
Self-Pressure Reducing Valve 347
Work Equipment Lock Solenoid Valve 352
Pilot Circuit Accumulator 353
Quick Drop Valve 354
Piston Valve 356
Electric Blade Control Lever 357
Ripper Electric Lever 358
Pin Puller Switch 359
Lifting System 360
Power Ladder System 360
Layout Drawing of Power Ladder System 360
Hydraulic Circuit Diagram of Power Ladder System 361
Function of Power Ladder System 361
Component Parts of Lifting System 363
Switch Box 363
Power Ladder Limit Switch Part 364
Control Valve Assembly 365
Undercarriage and Frame 366
Main Frame 366
Structure of Main Frame 366
Suspension 368
Structure of Suspension 368
Function of Suspension 370
Track Frame and Idler Cushion 371
Structure of Track Frame and Idler Cushion 371
Specifications of Track Frame and Idler Cushion 372
Function of Track Frame and Idler Cushion 372
Work Equipment 373
Structure of Front Work Equipment 373
Structure of Cylinder Stay 375
Structure of Variable Giant Ripper 376
Structure of Variable Multi-Shank Ripper 377
CAB Related Parts 378
ROPS 378
Structure of ROPS 378
Function of ROPS 378
CAB 379
Structure of CAB 379
CAB Mount 380
Structure of CAB Mount 380
20 Standard Value Table 381
Table of Contents 382
Standard Value Table for Engine 383
Standard Value Table for Engine: D375A-8 383
Standard Value Table for Machine 389
Standard Value Table for Machine: D375A-8 389
Machine Posture and Procedures to Measure Performance 413
30 Testing and Adjusting 417
Table of Contents 418
Precautions Before Work 421
Related Information on Testing and Adjusting 422
Tools for Testing and Adjusting 422
Sketch of Tools for Testing and Adjusting 428
Engine and Cooling System 430
Examine Engine Speed 430
How to Examine Engine Speed 430
Examine Boost Pressure 434
How to Examine Boost Pressure on Machine Monitor 434
How to Examine Boost Pressure by Testing Tool 435
Examine Exhaust Gas Temperature 437
How to Test Exhaust Gas Temperature by the Machine Monitor 437
How to Examine Exhaust Temperature by Testing Tools 438
Examine Exhaust Gas Color 441
How to Examine Exhaust Gas Color with the Handy Smoke Checker 441
How to Examine Exhaust Gas Color with Smoke Meter 442
Examine and Adjust Valve Clearance 445
How to Examine Valve Clearance 445
How to Adjust Valve Clearance 446
Examine Compression Pressure 448
How to Examine Compression Pressure 448
Examine Blowby Pressure 452
How to Examine Blowby Pressure 452
Examine Engine Oil Pressure 454
How to Examine Engine Oil Pressure on Machine Monitor 454
How to Examine Engine Oil Pressure by Testing Tool 454
Examine EGR Valve and VGT Oil Pressure 456
How to Examine EGR Valve and VGT Oil Pressure 456
Examine Fuel Pressure 457
How to Examine Fuel Pressure 457
Examine Fuel Return Rate and Leakage 459
How to Examine Fuel Return Rate and Leakage 460
Bleed Air from Fuel System 465
How to Bleed Air from Fuel System 465
Examine Fuel Circuit for Leakage 467
How to Examine Fuel System for Leakage 467
Examine Supply Pump 469
How to Examine Supply Pump 469
Handle Cylinder Cut-out Mode Operation 472
Handle No-Injection Cranking Operation 473
Clean Fuel Doser 474
How to Clean Fuel Doser 474
Write Injector Compensation Value to Engine Controller 477
How to Write Injector Compensation Value 477
Write Correction for Ash in Soot Accumulation to Engine Controller 483
How to Write Correction for Ash in Soot Accumulation to Engine Controller 483
Adjust Decelerator Pedal 484
How to Adjust Decelerator Pedal 484
Power Train 487
Examine Power Train Oil Pressure 487
How to Examine Power Train Oil Pressure 488
Adjust Transmission Output Shaft Speed Sensor 505
How to Adjust Transmission Output Shaft Speed Sensor 505
Examine Brake Performance Simply 507
How to Examine Brake Performance Simply 507
Examine and Adjust Brake Pedal 508
How to Examine Brake Pedal 508
How to Adjust Brake Pedal 509
Adjust Parking Brake Lever 512
How to Adjust Parking Brake Lever 512
Move Machine by Parking Brake Release When Machine Does Not Travel 514
How to Move Machine with Hydraulic Type Parking Brake Release System 514
How to Move Machine with Electric Type Parking Brake Release System 515
Undercarriage and Frame 518
Examine and Adjust Track Tension 518
How to Examine Track Tension 518
How to Adjust Track Tension 518
Hydraulic System 520
Release Remained Pressure in Hydraulic Circuit 520
How to Release Remained Pressure in Hydraulic System 520
Examine and Adjust Work Equipment Oil Pressure 521
How to Examine Work Equipment Oil Pressure 521
How to Adjust Work Equipment Oil Pressure 523
Examine Oil Pressure of Control Circuit 524
How to Examine Oil Pressure in Control Circuit 524
Examine Work Equipment Lock Solenoid Valve Outlet Pressure 526
How to Examine Work Equipment Lock Solenoid Valve Outlet Pressure 526
Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 528
How to Examine Ripper Pin Puller Solenoid Valve Outlet Pressure 528
Bleed Air from Work Equipment Pump 530
How to Bleed Air from Work Equipment Pump 530
Examine Cooling Fan Speed 531
How to Examine Cooling Fan Speed 531
Examine Cooling Fan Circuit Oil Pressure 532
How to Examine Cooling Fan Circuit Oil Pressure 532
Bleed Air in Cooling Fan Pump 534
How to Bleed Air in Cooling Fan Pump 534
Examine Parts Which Cause Hydraulic Drift of Work Equipment 535
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder 535
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder 535
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder 536
Examine Oil Leakage from Work Equipment Cylinder 537
How to Examine Internal Oil Leakage of Work Equipment Cylinder 537
Bleed Air from Work Equipment Cylinders 539
How to Bleed Air from Work Equipment Cylinder 539
Operation When Work Equipment is Disabled 540
How to Operate When Work Equipment is Disabled 540
Power Ladder 542
Bleed Air from Power Ladder Cylinder 542
How to Bleed Air in Power Ladder Cylinder 542
Examine and Adjust Power Ladder Limit Switch 547
How to Examine and Adjust Power Ladder Limit Switch 547
How to Adjust Power Ladder Limit Switch 547
Work Equipment 556
Adjust Work Equipment Lock Lever 556
How to Adjust Work Equipment Lock Lever 556
CAB Related Parts 558
Examine and Adjust Operator Cab 558
How to Examine Operator Cab 558
How to Adjust Operator Cab 561
Adjust Play of Operator Seat 564
How to Adjust Play of Operator Seat 564
Electrical System 565
Set and Operate Machine Monitor 565
Operator Mode 568
Function to Show Technician Identification Status Screen 568
Function to Show Operator Identification Input Screen 568
Examine Function by LCD (Liquid Crystal Display) 569
Examine Function of Service Meter 570
How to Set Usage Limitation and Change Maintenance Password 570
Service Mode 572
How to Operate Service Mode 572
How to See Pre-defined Monitoring Information 574
How to Examine Self-Define Monitor Information 579
Abnormality Record Menu 590
How to See Maintenance Record 595
Maintenance Mode Setting 596
How to Set Phone Number Entry 599
Default Menu 600
Diagnostic Tests Menu 609
Adjustment Menu 619
No-Injection Cranking Operation 683
KOMTRAX Settings Menu 684
How to Show Service Message 686
How to Operate Snap Shot 687
How to Start Up KOMTRAX Terminal 690
Default Setting of KOMTRAX Plus Controller 695
How to do the Default Setting of KOMTRAX Plus Controller 695
Default Setting of Wireless LAN Modem 698
Default Setting of Wireless LAN Modem 698
How to Examine Wireless LAN Modem Communication 699
Download Data from KOMTRAX Plus Controller 700
How to Download Data from KOMTRAX Plus Controller 700
Adjust After Replacement of KOMTRAX Plus Controller 703
How to Adjust After Replacement of KOMTRAX Plus Controller 703
Adjust After Replacement of Wireless LAN Modem 706
How to Adjust After Replacement of Wireless LAN Modem 706
Adjust Rearview Camera Angle 709
How to Adjust Rearview Camera Angle 709
Handle Voltage Circuit of Engine Controller 710
Handle Battery Disconnect Switch 711
Examine Diodes 712
How to Examine Diodes by Digital Tester 712
How to Examine Diodes by Analog Tester 712
Pm Clinic 713
Pm Clinic Service 713
Pm Clinic Check Sheet: D375A-8 714
Pm Clinic Check Sheet for Undercarriage: D375A-8 732
Perform Quick Pm 737
How to Perform Quick Pm 737
40 Troubleshooting 741
Table of Contents 742
Precautions Before Work 754
Related Information to Troubleshooting 755
General Troubleshooting Points 755
Troubleshooting Points for Aftertreatment System 756
Sequence of Events in Troubleshooting 763
Checks Before Troubleshooting 765
Inspection Procedure Before Troubleshooting 767
Walk-Around Check 767
Test in Accordance with Testing Procedure 769
How to Drain Water and Sediment from Fuel Tank 769
How to Examine Water Separator, Drain Water and Sediment 769
Examine Fuel Main Filter 770
How to Examine Oil Level in Hydraulic Tank, Add Oil 771
How to Examine Coolant Level, Add Coolant 773
How to Examine Oil Level in Engine Oil Pan, Add Oil 774
How to Examine Oil Level in Power Train Case, Add Oil 775
How to Examine Dust Indicator 776
How to Examine Brake Operation 777
How to Examine Electric Wiring 777
How to Examine Fuel Level, Add Fuel 777
How to Examine Operation of Lamps 778
How to Examine Machine Monitor 778
How to Remove Sediment in Engine Room 779
How to Examine Operation State of Horn 779
How to Examine Operation State of Backup Alarm 780
How to Examine Electric Equipment 780
Preparation for Troubleshooting of Electrical System 785
Preparation for Troubleshooting of Machine Monitor 785
Preparation for Troubleshooting of Engine Controller 785
Preparation for Troubleshooting of Work Equipment Controller 785
Preparation for Troubleshooting of Power Train Controller 786
Preparation for Troubleshooting of KOMTRAX Terminal 786
How to Disconnect and Connect Connector with a Special Lock 786
Procedure for Troubleshooting 791
Symptom and Troubleshooting Numbers 794
Information Shown in Troubleshooting Table 797
How to Diagnose Open Circuit of Hydraulic Pressure Sensor System Wiring Harness 799
Connector List and Layout 802
Connector Contact Connection Table 824
T-Branch Box and T-Branch Adapter Table 864
Fuse Location Table 870
Precautions When You Clean and Replace KDPF (KCSF and KDOC) 874
Prepare of Short Socket Adapter (For Failure Codes [CA1883], [CB1883], [CA3135] and [CB3135]) 878
Failure Code Table 880
Troubleshooting by Failure Code (Display of Code) 904
Failure Code [1500L0] 904
Failure Code [15B0NX] 905
Failure Code [15SAL1] 907
Failure Code [15SALH] 909
Failure Code [15SBL1] 911
Failure Code [15SBLH] 913
Failure Code [15SEL1] 915
Failure Code [15SELH] 917
Failure Code [15SFL1] 919
Failure Code [15SFLH] 921
Failure Code [15SGL1] 923
Failure Code [15SGLH] 925
Failure Code [15SJL1] 927
Failure Code [15SJLH] 929
Failure Code [1800MW] 931
Failure Code [2201L1] 932
Failure Code [2201LH] 934
Failure Code [2202L1] 936
Failure Code [2202LH] 937
Failure Code [2300NR] 939
Failure Code [2301L1] 940
Failure Code [2301LH] 942
Failure Code [2301NR] 944
Failure Code [2301NT] 945
Failure Code [2302L1] 946
Failure Code [2302LH] 948
Failure Code [2302NR] 950
Failure Code [2302NT] 951
Failure Code [879AKA] 952
Failure Code [879AKB] 953
Failure Code [879BKA] 954
Failure Code [879BKB] 956
Failure Code [879CKA] 958
Failure Code [879CKB] 959
Failure Code [879DKZ] 960
Failure Code [879EMC] 962
Failure Code [879FMC] 963
Failure Code [879GKX] 964
Failure Code [989L00] 966
Failure Code [989M00] 967
Failure Code [989N00] 968
Failure Code [A1U0N3] 969
Failure Code [A1U0N4] 971
Failure Code [A900FR] 973
Failure Code [A900N6] 974
Failure Code [A900NY] 975
Failure Code [AA10NX] 976
Failure Code [AB00KE] 978
Failure Code [AQ00N3] 980
Failure Code [AQ00N4] 981
Failure Code [AQ10N3] 982
Failure Code [B@BAZG] 983
Failure Code [B@BAZK] 984
Failure Code [B@BCNS] 985
Failure Code [B@BCZK] 986
Failure Code [B@CENS] 988
Failure Code [B@HANS] 990
Failure Code [B@HAZK] 992
Failure Code [CA115] 993
Failure Code [CA122] 997
Failure Code [CA123] 999
Failure Code [CA131] 1001
Failure Code [CA132] 1003
Failure Code [CA135] 1005
Failure Code [CA141] 1007
Failure Code [CA144] 1009
Failure Code [CA145] 1011
Failure Code [CA153] 1013
Failure Code [CA154] 1015
Failure Code [CA187] 1017
Failure Code [CA212] 1019
Failure Code [CA213] 1021
Failure Code [CA221] 1023
Failure Code [CA222] 1025
Failure Code [CA227] 1027
Failure Code [CA234] 1029
Failure Code [CA238] 1030
Failure Code [CA239] 1032
Failure Code [CA271] 1034
Failure Code [CA272] 1036
Failure Code [CA273] 1037
Failure Code [CA274] 1039
Failure Code [CA322] 1040
Failure Code [CA323] 1042
Failure Code [CA324] 1044
Failure Code [CA325] 1046
Failure Code [CA331] 1048
Failure Code [CA332] 1050
Failure Code [CA343] 1052
Failure Code [CA351] 1054
Failure Code [CA352] 1056
Failure Code [CA356] 1058
Failure Code [CA357] 1060
Failure Code [CA386] 1062
Failure Code [CA441] 1064
Failure Code [CA442] 1066
Failure Code [CA449] 1068
Failure Code [CA451] 1069
Failure Code [CA452] 1071
Failure Code [CA515] 1073
Failure Code [CA516] 1074
Failure Code [CA553] 1075
Failure Code [CA555] 1076
Failure Code [CA556] 1078
Failure Code [CA559] 1080
Failure Code [CA595] 1086
Failure Code [CA687] 1088
Failure Code [CA689] 1090
Failure Code [CA691] 1092
Failure Code [CA692] 1094
Failure Code [CA697] 1096
Failure Code [CA698] 1097
Failure Code [CA731] 1098
Failure Code [CA778] 1102
Failure Code [CA1117] 1104
Failure Code [CA1135] 1106
Failure Code [CA1257] 1109
Failure Code [CA1664] 1110
Failure Code [CA1691] 1112
Failure Code [CA1695] 1115
Failure Code [CA1696] 1117
Failure Code [CA1843] 1119
Failure Code [CA1844] 1121
Failure Code [CA1879] 1123
Failure Code [CA1881] 1125
Failure Code [CA1883] 1127
Failure Code [CA1921] 1130
Failure Code [CA1922] 1132
Failure Code [CA1923] 1136
Failure Code [CA1924] 1138
Failure Code [CA1925] 1140
Failure Code [CA1927] 1142
Failure Code [CA1928] 1144
Failure Code [CA1942] 1146
Failure Code [CA1963] 1148
Failure Code [CA1977] 1152
Failure Code [CA1993] 1154
Failure Code [CA2185] 1157
Failure Code [CA2186] 1159
Failure Code [CA2249] 1161
Failure Code [CA2265] 1166
Failure Code [CA2266] 1168
Failure Code [CA2271] 1170
Failure Code [CA2272] 1172
Failure Code [CA2349] 1174
Failure Code [CA2353] 1176
Failure Code [CA2357] 1178
Failure Code [CA2381] 1181
Failure Code [CA2382] 1183
Failure Code [CA2383] 1185
Failure Code [CA2386] 1187
Failure Code [CA2387] 1189
Failure Code [CA2637] 1192
Failure Code [CA2639] 1195
Failure Code [CA2732] 1197
Failure Code [CA2733] 1199
Failure Code [CA2741] 1201
Failure Code [CA2765] 1202
Failure Code [CA2777] 1203
Failure Code [CA2878] 1205
Failure Code [CA2881] 1208
Failure Code [CA3133] 1211
Failure Code [CA3134] 1213
Failure Code [CA3135] 1215
Failure Code [CA3167] 1218
Failure Code [CA3251] 1221
Failure Code [CA3253] 1223
Failure Code [CA3254] 1227
Failure Code [CA3255] 1230
Failure Code [CA3256] 1233
Failure Code [CA3311] 1235
Failure Code [CA3312] 1237
Failure Code [CA3313] 1239
Failure Code [CA3314] 1240
Failure Code [CA3315] 1241
Failure Code [CA3316] 1244
Failure Code [CA3317] 1245
Failure Code [CA3318] 1246
Failure Code [CA3319] 1249
Failure Code [CA3321] 1250
Failure Code [CA3322] 1251
Failure Code [CA3419] 1254
Failure Code [CA3421] 1256
Failure Code [CA4151] 1258
Failure Code [CA4158] 1262
Failure Code [CA4161] 1263
Failure Code [CA4162] 1265
Failure Code [CA4163] 1267
Failure Code [CA4259] 1269
Failure Code [CA4952] 1272
Failure Code [CA5383] 1274
Failure Code [CB115] 1275
Failure Code [CB187] 1278
Failure Code [CB227] 1280
Failure Code [CB238] 1281
Failure Code [CB239] 1283
Failure Code [CB271] 1285
Failure Code [CB272] 1287
Failure Code [CB273] 1288
Failure Code [CB274] 1290
Failure Code [CB343] 1291
Failure Code [CB352] 1293
Failure Code [CB386] 1295
Failure Code [CB441] 1297
Failure Code [CB442] 1299
Failure Code [CB689] 1301
Failure Code [CB697] 1303
Failure Code [CB698] 1304
Failure Code [CB731] 1305
Failure Code [CB778] 1309
Failure Code [CB1117] 1311
Failure Code [CB1257] 1313
Failure Code [CB1664] 1314
Failure Code [CB1691] 1316
Failure Code [CB1695] 1319
Failure Code [CB1696] 1321
Failure Code [CB1879] 1323
Failure Code [CB1881] 1325
Failure Code [CB1883] 1327
Failure Code [CB1921] 1330
Failure Code [CB1922] 1332
Failure Code [CB1923] 1336
Failure Code [CB1924] 1338
Failure Code [CB1925] 1340
Failure Code [CB1927] 1342
Failure Code [CB1928] 1344
Failure Code [CB1963] 1346
Failure Code [CB1977] 1350
Failure Code [CB1993] 1352
Failure Code [CB2265] 1355
Failure Code [CB2266] 1357
Failure Code [CB2637] 1359
Failure Code [CB2639] 1362
Failure Code [CB2732] 1364
Failure Code [CB2733] 1366
Failure Code [CB2741] 1368
Failure Code [CB2777] 1370
Failure Code [CB2878] 1372
Failure Code [CB2881] 1375
Failure Code [CB3133] 1378
Failure Code [CB3134] 1380
Failure Code [CB3135] 1382
Failure Code [CB3167] 1385
Failure Code [CB3251] 1388
Failure Code [CB3253] 1390
Failure Code [CB3254] 1395
Failure Code [CB3255] 1398
Failure Code [CB3256] 1401
Failure Code [CB3311] 1403
Failure Code [CB3312] 1405
Failure Code [CB3313] 1407
Failure Code [CB3314] 1408
Failure Code [CB3315] 1409
Failure Code [CB3316] 1412
Failure Code [CB3317] 1413
Failure Code [CB3318] 1414
Failure Code [CB3319] 1417
Failure Code [CB3321] 1418
Failure Code [CB3322] 1419
Failure Code [CB4151] 1422
Failure Code [CB4158] 1426
Failure Code [CB4161] 1427
Failure Code [CB4162] 1429
Failure Code [CB4163] 1431
Failure Code [CB4259] 1434
Failure Code [CB4952] 1437
Failure Code [CB5383] 1439
Failure Code [D130KA] 1440
Failure Code [D130KB] 1442
Failure Code [D182KZ] 1443
Failure Code [D19JKZ] 1445
Failure Code [D1D5KA] 1447
Failure Code [D1D5KB] 1449
Failure Code [D1D5KY] 1451
Failure Code [D1EFKA] 1452
Failure Code [D1EFKB] 1454
Failure Code [D1EWKA] 1456
Failure Code [D1EWKB] 1457
Failure Code [D1EWKY] 1458
Failure Code [D862KA] 1459
Failure Code [DAF0MB] 1460
Failure Code [DAF0MC] 1461
Failure Code [DAF8KB] 1462
Failure Code [DAF9KQ] 1463
Failure Code [DAFGMC] 1464
Failure Code [DAFLKA] 1465
Failure Code [DAFLKB] 1468
Failure Code [DAFQKR] 1470
Failure Code [DAQW00] 1475
Failure Code [DAZ9KQ] 1476
Failure Code [DAZQKR] 1477
Failure Code [DB2QKR] 1481
Failure Code [DB2RKR] 1487
Failure Code [DB90KT] 1492
Failure Code [DB90MC] 1493
Failure Code [DB91KK] 1494
Failure Code [DB92KK] 1497
Failure Code [DB95KK] 1500
Failure Code [DB97KK] 1502
Failure Code [DB99KQ] 1504
Failure Code [DB9LKA] 1505
Failure Code [DB9LKB] 1507
Failure Code [DB9QKR] 1509
Failure Code [DB9RKR] 1514
Failure Code [DBE0KT] 1519
Failure Code [DBE0MC] 1520
Failure Code [DBE1KK] 1521
Failure Code [DBE2KK] 1524
Failure Code [DBE5KK] 1527
Failure Code [DBE6KK] 1529
Failure Code [DBE9KQ] 1531
Failure Code [DBELKA] 1532
Failure Code [DBELKB] 1535
Failure Code [DBEQKR] 1537
Failure Code [DBERKR] 1542
Failure Code [DBV0MC] 1547
Failure Code [DBV1KK] 1548
Failure Code [DBVLKA] 1550
Failure Code [DBVLKB] 1552
Failure Code [DBVQKR] 1554
Failure Code [DBVRKR] 1555
Failure Code [DBVVKR] 1556
Failure Code [DBVWKR] 1557
Failure Code [DD12KA] 1558
Failure Code [DD12KB] 1560
Failure Code [DD13KA] 1562
Failure Code [DD13KB] 1564
Failure Code [DD14KA] 1566
Failure Code [DD14KB] 1568
Failure Code [DDDDKA] 1570
Failure Code [DDDDKB] 1572
Failure Code [DDDDKX] 1574
Failure Code [DDDHKB] 1575
Failure Code [DDDKKA] 1577
Failure Code [DDDKKB] 1579
Failure Code [DDDLKA] 1581
Failure Code [DDDLKB] 1583
Failure Code [DDE2KA] 1585
Failure Code [DDKAKA] 1586
Failure Code [DDKAKB] 1588
Failure Code [DDKBKA] 1590
Failure Code [DDKBKB] 1592
Failure Code [DDKCL4] 1594
Failure Code [DDKEL4] 1596
Failure Code [DDN7L4] 1598
Failure Code [DDN8L4] 1600
Failure Code [DDNLKA] 1602
Failure Code [DDNLKB] 1604
Failure Code [DDTSL1] 1606
Failure Code [DDTSLH] 1608
Failure Code [DFA4KX] 1610
Failure Code [DFA4KZ] 1611
Failure Code [DFA4L8] 1612
Failure Code [DFA5KA] 1614
Failure Code [DFA5KY] 1616
Failure Code [DFA6KA] 1618
Failure Code [DFA6KY] 1620
Failure Code [DFA7KX] 1622
Failure Code [DFA7KZ] 1623
Failure Code [DFA7L8] 1624
Failure Code [DFA8KA] 1626
Failure Code [DFA8KY] 1628
Failure Code [DFA9KA] 1630
Failure Code [DFA9KY] 1632
Failure Code [DFAAKX] 1634
Failure Code [DFAAKZ] 1635
Failure Code [DFAAL8] 1636
Failure Code [DFABKA] 1638
Failure Code [DFABKY] 1640
Failure Code [DFACKA] 1642
Failure Code [DFACKY] 1644
Failure Code [DGS1KA] 1646
Failure Code [DGS1KX] 1648
Failure Code [DGT1KA] 1650
Failure Code [DGT1KX] 1652
Failure Code [DGT4KA] 1654
Failure Code [DGT4KY] 1656
Failure Code [DH21KA] 1658
Failure Code [DH21KY] 1660
Failure Code [DHA4KA] 1662
Failure Code [DHAAMA] 1664
Failure Code [DHABMA] 1665
Failure Code [DHACMA] 1666
Failure Code [DHADMA] 1667
Failure Code [DHT2L6] 1668
Failure Code [DHT3KX] 1669
Failure Code [DHT5KA] 1670
Failure Code [DHT5KY] 1672
Failure Code [DHT7KA] 1674
Failure Code [DHT7KY] 1676
Failure Code [DK10KA] 1678
Failure Code [DK10KB] 1680
Failure Code [DK30KA] 1682
Failure Code [DK30KX] 1684
Failure Code [DK30KY] 1685
Failure Code [DK30KZ] 1687
Failure Code [DK30L8] 1688
Failure Code [DK31KA] 1690
Failure Code [DK31KY] 1692
Failure Code [DK40KA] 1694
Failure Code [DK40KY] 1696
Failure Code [DK55KX] 1698
Failure Code [DK55KZ] 1699
Failure Code [DK55L8] 1700
Failure Code [DK56KA] 1701
Failure Code [DK56KY] 1703
Failure Code [DK57KA] 1705
Failure Code [DK57KY] 1707
Failure Code [DK60KA] 1709
Failure Code [DK60KY] 1711
Failure Code [DKH1KA] 1713
Failure Code [DKH1KY] 1715
Failure Code [DLM3KA] 1717
Failure Code [DLM3MB] 1718
Failure Code [DLT3KA] 1719
Failure Code [DLT3KB] 1721
Failure Code [DNDAMC] 1723
Failure Code [DNDBKA] 1725
Failure Code [DNDBKB] 1727
Failure Code [DNDCKA] 1729
Failure Code [DNDCKB] 1731
Failure Code [DNDDKA] 1733
Failure Code [DNDDKB] 1735
Failure Code [DNDEKA] 1737
Failure Code [DNDEKB] 1739
Failure Code [DR21KX] 1741
Failure Code [DR31KX] 1742
Failure Code [DV20KB] 1743
Failure Code [DW7BKA] 1745
Failure Code [DW7BKB] 1747
Failure Code [DWN3KA] 1748
Failure Code [DWN3KB] 1750
Failure Code [DWN3KY] 1752
Failure Code [DWN5KA] 1753
Failure Code [DWN5KB] 1755
Failure Code [DWN5KY] 1757
Failure Code [DWNCKA] 1758
Failure Code [DWNCKB] 1760
Failure Code [DWNCKY] 1761
Failure Code [DWNVKA] 1762
Failure Code [DWNVKB] 1764
Failure Code [DWNWKA] 1766
Failure Code [DWNWKB] 1768
Failure Code [DWNXKA] 1770
Failure Code [DWNXKB] 1772
Failure Code [DWNYKA] 1774
Failure Code [DWNYKB] 1776
Failure Code [DXH1KA] 1778
Failure Code [DXH1KB] 1780
Failure Code [DXH1KY] 1782
Failure Code [DXH4KA] 1783
Failure Code [DXH4KB] 1785
Failure Code [DXH4KY] 1787
Failure Code [DXH5KA] 1788
Failure Code [DXH5KB] 1790
Failure Code [DXH5KY] 1792
Failure Code [DXH6KA] 1793
Failure Code [DXH6KB] 1795
Failure Code [DXH6KY] 1797
Failure Code [DXH7KA] 1798
Failure Code [DXH7KB] 1800
Failure Code [DXH7KY] 1802
Failure Code [DXH8KA] 1803
Failure Code [DXH8KB] 1805
Failure Code [DXH8KY] 1807
Failure Code [DXH9KA] 1808
Failure Code [DXH9KB] 1810
Failure Code [DXH9KY] 1812
Failure Code [DXHAKA] 1813
Failure Code [DXHAKB] 1815
Failure Code [DXHAKY] 1817
Failure Code [DXHBKA] 1818
Failure Code [DXHBKB] 1820
Failure Code [DXHBKY] 1822
Failure Code [DXHCKA] 1823
Failure Code [DXHCKB] 1825
Failure Code [DXHCKY] 1827
Failure Code [DXHRKA] 1828
Failure Code [DXHRKB] 1830
Failure Code [DXHRKY] 1832
Failure Code [DXHSKA] 1833
Failure Code [DXHSKB] 1835
Failure Code [DXHSKY] 1837
Failure Code [DXHTKA] 1838
Failure Code [DXHTKB] 1840
Failure Code [DXHTKY] 1842
Failure Code [DXHUKA] 1843
Failure Code [DXHUKB] 1845
Failure Code [DXHUKY] 1847
Failure Code [DXHWKA] 1848
Failure Code [DXHWKB] 1850
Failure Code [DXHWKY] 1852
Failure Code [DXHXKA] 1853
Failure Code [DXHXKB] 1855
Failure Code [DXHXKY] 1857
Failure Code [DXHYKA] 1858
Failure Code [DXHYKB] 1860
Failure Code [DXHYKY] 1862
Failure Code [DXHZKA] 1863
Failure Code [DXHZKB] 1865
Failure Code [DXHZKY] 1867
Failure Code [DXJ4KA] 1868
Failure Code [DXJ4KB] 1870
Failure Code [DXJ8KA] 1871
Failure Code [DXJ8KB] 1873
Failure Code [DXJ8KY] 1875
Failure Code [DXJ9KA] 1876
Failure Code [DXJ9KB] 1878
Failure Code [DXJ9KY] 1880
Failure Code [DXJBKA] 1881
Failure Code [DXJBKB] 1883
Failure Code [DXJBKY] 1884
Failure Code [DY2HKA] 1885
Failure Code [F9A0KT] 1887
Failure Code [F9A0MC] 1888
Failure Code [F9A1KK] 1889
Failure Code [F9A2KK] 1891
Failure Code [F9AQKR] 1893
Failure Code [F9ARKR] 1898
Failure Code [F9ATKA] 1903
Failure Code [F9ATKB] 1906
Failure Code [F9AUMC] 1908
Failure Code [F@BYNR] 1910
Failure Code [F@BYNS] 1911
Troubleshooting of Electrical System (E-Mode) 1912
E-1 Engine Does Not Start (Engine Does Not Crank) 1912
E-2 Manual Preheating System Does Not Operate 1916
E-3 Automatic Preheating System Does Not Operate 1919
E-4 While Preheating is in Operation, Preheating Monitor Does Not Come On 1921
E-5 When Starting Switch is Turned to ON Position, Machine Monitor Shows Nothing 1923
E-6 While Starting Switch is Turned to ON Position (with Engine Stopped), Radiator Coolant Level Monitor Comes On in Yellow 1927
E-7 Air Cleaner Clogging Monitor Comes On in Yellow While Engine is in Operation 1929
E-8 Charge Level Monitor Comes On in Red While Engine is in Operation 1930
E-9 Engine Coolant Temperature Monitor Comes On in Red While Engine is in Operation 1932
E-10 Engine Oil Pressure Monitor Comes on in Red While Engine is in Operation 1933
E-11 Power Train Oil Temperature Monitor Comes On in Red While Engine is in Operation 1934
E-12 Hydraulic Oil Temperature Monitor Comes On in Red While Engine is in Operation 1935
E-13 Engine Coolant Temperature Gauge Does Not Show Correct Temperature 1936
E-14 Fuel Gauge Does Not Show Normally 1937
E-15 Power Train Oil Temperature Gauge Does Not Show Correct Temperature 1939
E-16 Hydraulic Oil Temperature Gauge Does Not Show Correct Temperature 1941
E-17 Operation Mode Does Not Change 1943
E-18 Gear Shift Mode Does Not Change 1944
E-19 Operating Customize Switch Does Not Display Customize Screen 1945
E-20 Modifying Setting on Customize Screen Does Not Change Setting of Machine 1946
E-21 Some Areas of Machine Monitor Screen are Not Shown 1947
E-22 Alarm Buzzer Does Not Sound or Cannot be Stopped 1948
E-23 Service Meter is Not Shown, While Starting Switch is in OFF Position 1949
E-24 Machine Does Not Change to Service Mode 1950
E-25 Horn Does Not Sound 1951
E-26 Horn Does Not Stop 1953
E-27 Backup Alarm Does Not Sound 1954
E-28 Backup Alarm Does Not Stop 1955
E-29 Headlamp Does Not Come On 1956
E-30 Rear Lamp and Ripper Point Lamp Do Not Come On 1960
E-31 No Wiper Operates 1964
E-32 Front Wiper Does Not Operate 1969
E-33 Rear Wiper Does Not Operate 1973
E-34 Left Door Wiper Does Not Operate 1977
E-35 Right Door Wiper Does Not Operate 1981
E-1 Fuel Feed Pump Does Not Operate or Stop Automatically 1985
E-37 Fan Does Not Rotate in Reverse 1987
E-38 Gear Cannot be Shifted 1988
E-39 Front Washer Does Not Operate 1989
E-40 Rear Washer Does Not Operate 1991
E-41 Left Door Washer Does Not Operate 1993
E-42 Right Door Washer Does Not Operate 1995
E-43 Ripper Pin Puller Does Not Work 1997
E-44 KOMTRAX Plus System Does Not Operate Normally 1999
E-45 Cannot Download Data with Wireless LAN 2000
Troubleshooting for Hydraulic and Mechanical Systems (H Mode) 2001
Information Shown in Troubleshooting Table (H-Mode) 2001
H-1 Machine Power is Not Sufficient (Not Sufficient Drawbar Pull) 2002
H-2 Machine Does Not Travel (at 2nd or 3rd Gear Speed) 2005
H-3 Machine Does Not Move Off at All Gear Speeds 2007
H-4 Machine Travels Only in One Direction, Forward or in Reverse 2009
H-5 Large Time Lag is in Gear Shifting or Directional Change 2010
H-6 Brake Does Not Work 2012
H-7 Power Train Oil Overheats 2013
H-8 Torque Converter Lockup Clutch Does Not Engage 2014
H-9 Machine Cannot be Steered (Machine Does Not Turn LEFT or RIGHT) 2015
H-10 Machine Can Turn (Steering) Only in One Direction 2016
H-11 Machine Falls Over Too Much (Steering) 2017
H-12 All Work Equipment Operate Slowly 2018
H-13 All Work Equipment Do Not Operate 2020
H-14 Blade Lift Speed or Power is Low 2022
H-15 Blade Tilt Speed or Power is Low 2024
H-16 Ripper Lift Speed or Power is Low 2026
H-17 Ripper Tilt Speed or Power is Low 2028
H-18 Hydraulic Drift of Blade Lift is Large 2030
H-19 Hydraulic Drift of Tilted Blade is Large 2031
H-20 Hydraulic Drift of Lifted Ripper is Large 2032
H-21 Ripper Pin Puller Cylinder Does Not Operate 2033
H-22 Blade Pitch Cylinder Does Not Operate 2034
H-23 Unusual Noise is Heard from Around Work Equipment and Cooling Fan Pump or Control Valve 2035
H-24 Fan Speed is Abnormal (Too High or Low, or Does Not Rotate) 2036
H-25 Seismic Isolation Operator Seat Shakes Abnormally or Receives Shock 2037
Troubleshooting of Engine (S-Mode) 2038
Information Shown in Troubleshooting Table (S-Mode) 2038
S-1 Engine Does Not Crank When Starting Switch is Turned to Start Position 2039
S-2 Engine Cranks but No Exhaust Smoke Comes Out 2040
S-3 Fuel is Injected but Engine Does Not Start (Misfiring: Engine Cranks but Does Not Start) 2041
S-4 Engine Startability is Unsatisfactory 2042
S-5 Engine Does Not Pick Up Smoothly 2044
S-6 Engine Stops During Operation 2046
S-7 Engine Runs Rough or is Not Stable 2048
S-8 Engine Lacks Power 2049
S-9 KDPF Becomes Clogged in a Short Time 2051
S-10 Engine Oil Consumption is Excessive 2053
S-11 Oil Becomes Dirty Quickly 2054
S-1 Fuel Consumption is Excessive 2055
S-13 Oil is in Coolant (or Coolant Spurts Back or Coolant 2056
S-14 Oil Pressure Drops 2057
S-15 Fuel Mixes Into Engine Oil 2059
S-16 Water Mixes Into Engine Oil (Milky) 2060
S-17 Coolant Temperature Increases Too High (Overheating) 2061
S-18 Unusual Noise is Heard 2063
S-19 Vibration is Excessive 2064
S-2 Air Cannot be Bled from Fuel Circuit 2065
S-21 Active Regeneration is Done Frequently 2066
S-22 Active Regeneration Continues Long 2067
S-23 White Smoke is Exhausted During Active Regeneration 2068
50 Disassembly and Assembly 2069
Table of Contents 2070
Precautions Before Work 2076
Related Information on Disassembly and Assembly 2077
How to Read This Manual 2077
Coating Materials List 2079
Special Tool List 2084
Sketches of Special Tools 2109
Engine and Cooling System 2135
Remove and Install Supply Pump Assembly 2135
How to Remove Supply Pump Assembly 2135
How to Install Supply Pump Assembly 2143
Remove and Install Injector Assembly 2154
How to Remove Injector Assembly 2155
How to Install Injector Assembly 2163
Remove and Install Fuel Doser Assembly 2176
How to Remove Fuel Doser Assembly 2176
How to Install Fuel Doser Assembly 2178
Remove and Install Cylinder Head Assembly 2181
How to Remove Cylinder Head Assembly 2182
How to Install Cylinder Head Assembly 2204
Remove and Install Common Rail 2235
How to Remove Common Rail 2235
How to Install Common Rail 2241
Remove and Install EGR Valve Assembly 2248
How to Remove EGR Valve Assembly 2248
How to Install EGR Valve Assembly 2249
Remove and Install EGR Cooler Assembly 2250
How to Remove EGR Cooler Assembly 2250
How to Install EGR Cooler Assembly 2255
Remove and Install Starter Assembly 2260
How to Remove Starting Motor Assembly 2260
How to Install Starting Motor Assembly 2261
Remove and Install Radiator Guard Assembly 2263
How to Remove Radiator Guard Assembly 2263
How to Install Radiator Guard Assembly 2269
Remove and Install Cooler Assembly 2276
How to Remove Cooling Assembly 2276
How to Install Cooling Assembly 2281
Remove and Install Radiator Assembly 2285
How to Remove Radiator Assembly 2285
How to Install Radiator Assembly 2287
Remove and Install Hydraulic Oil Cooler Assembly 2289
How to Remove Hydraulic Oil Cooler Assembly 2289
How to Install Hydraulic Oil Cooler Assembly 2291
Remove and Install Aftercooler Assembly 2293
How to Remove Aftercooler Assembly 2293
How to Install Aftercooler Assembly 2295
Open and Close Cooling Fan Drive Assembly 2297
How to Open Cooling Fan Drive Assembly 2297
How to Close Cooling Fan Drive Assembly 2300
Remove and Install Cooling Fan Drive Assembly 2303
How to Remove Cooling Fan Drive Assembly 2303
How to Install Cooling Fan Drive Assembly 2307
Remove and Install Cooling Fan Motor Assembly 2310
How to Remove Cooling Fan Motor Assembly 2310
How to Install Cooling Fan Motor Assembly 2312
Remove and Install Engine Assembly 2314
How to Remove Engine Assembly 2314
How to Install Engine Assembly 2327
Remove and Install Engine Front Oil Seal 2340
How to Remove Engine Front Oil Seal 2340
How to Install Engine Front Oil Seal 2341
Remove and Install Engine Rear Oil Seal 2343
How to Remove Engine Rear Oil Seal 2343
How to Install Engine Rear Oil Seal 2344
Remove and Install Engine Hood Assembly 2348
How to Remove Engine Hood Assembly 2348
How to Install Engine Hood Assembly 2353
Remove and Install Fuel Tank Assembly 2360
How to Remove Fuel Tank Assembly 2360
How to Install Fuel Tank Assembly 2364
Remove and Install KDPF Assembly 2369
How to Remove KDPF Assembly 2369
How to Install KDPF Assembly 2374
Disassemble and Assemble KDPF Assembly 2379
How to Disassemble KDPF Assembly 2380
How to Assemble KDPF Assembly 2385
Remove and Install KCCV Assembly 2392
How to Remove KCCV Assembly 2392
How to Install KCCV Assembly 2394
Remove and Install VGT Assembly 2398
How to Remove VGT Assembly 2398
How to Install VGT Assembly 2406
Remove and Install Air Cleaner Bracket Assembly 2416
How to Remove Air Cleaner Bracket Assembly 2416
How to Install Air Cleaner Bracket Assembly 2421
Remove and Install Air Cleaner Assembly 2426
How to Remove Air Cleaner Assembly 2426
How to Install Air Cleaner Assembly 2427
Remove and Install Air Conditioner Compressor Assembly 2428
How to Remove Air Conditioner Compressor Assembly 2428
How to Install Air Conditioner Compressor Assembly 2431
Remove and Install Air Conditioner Condenser Assembly 2434
How to Remove Air Conditioner Condenser Assembly 2434
How to Install Air Conditioner Condenser Assembly 2437
Power Train 2440
Remove and Install Damper Assembly 2440
How to Remove Damper Assembly 2440
How to Install Damper Assembly 2448
Disassemble and Assemble Damper Assembly 2458
How to Disassemble Damper Assembly 2458
How to Assemble Damper Assembly 2459
Remove and Install Power Train Unit Assembly 2462
How to Remove Power Train Unit Assembly 2462
How to Install Power Train Unit Assembly 2475
Disconnect and Connect Power Train Unit Assembly 2488
How to Disconnect Power Train Unit Assembly 2488
How to Connect Power Train Unit Assembly 2497
Disassemble and Assemble PTO Assembly 2507
How to Disassemble PTO Assembly 2507
How to Assemble PTO Assembly 2510
Disassemble and Assemble Torque Converter Assembly 2515
How to Disassemble Torque Converter Assembly 2515
How to Assemble Torque Converter Assembly 2519
Disassemble and Assemble Transmission Assembly 2526
How to Disassemble Transmission Assembly 2527
How to Assemble Transmission Assembly 2539
Disassemble and Assemble Steering Case Assembly 2557
How to Disassemble Steering Case Assembly 2557
How to Assemble Steering Case Assembly 2564
Remove and Install Final Drive Assembly 2574
How to Remove Final Drive Assembly 2574
How to Install Final Drive Assembly 2575
Disassemble and Assemble Final Drive Assembly 2577
How to Disassemble Final Drive Assembly 2578
How to Assemble Final Drive Assembly 2584
Undercarriage and Frame 2594
Remove and Install Track Frame Assembly 2594
How to Remove Track Frame Assembly 2594
How to Install Track Frame Assembly 2598
Remove and Install Idler Assembly 2603
How to Remove Idler Assembly 2603
How to Install Idler Assembly 2604
Disassemble and Assemble Idler Assembly 2605
How to Disassemble Idler Assembly 2605
How to Assemble Idler Assembly 2606
Remove and Install Recoil Spring Assembly 2609
How to Remove Recoil Spring Assembly 2610
How to Install Recoil Spring Assembly 2618
Disassemble and Assemble Recoil Spring Assembly 2623
How to Disassemble Recoil Spring Assembly 2623
How to Assemble Recoil Spring Assembly 2624
Remove and Install Track Roller Assembly 2625
How to Remove Track Roller Assembly 2625
How to Install Track Roller Assembly 2627
Disassemble and Assemble Track Roller Assembly 2629
How to Disassemble Track Roller Assembly 2629
How to Assemble Track Roller Assembly 2630
Remove and Install No 1 Bogie Assembly 2632
How to Remove No 1 Bogie Assembly 2633
How to Install No 1 Bogie Assembly 2635
Remove and Install Bogie Assembly 2638
How to Remove Bogie Assembly 2639
How to Install Bogie Assembly 2642
Disassemble and Assemble Bogie Assembly 2644
How to Disassemble Bogie Assembly 2644
How to Assemble Bogie Assembly 2645
Remove and Install Carrier Roller Assembly 2647
How to Remove Carrier Roller Assembly 2647
How to Install Carrier Roller Assembly 2647
Disassemble and Assemble Carrier Roller Assembly 2649
How to Disassemble Carrier Roller Assembly 2649
How to Assemble Carrier Roller Assembly 2650
Remove and Install Pivot Shaft Assembly 2654
How to Remove Pivot Shaft Assembly 2654
How to Install Pivot Shaft Assembly 2655
Separate and Connect Track Assembly 2656
How to Separate Track Assembly 2656
How to Install Track Assembly 2658
Disassemble and Assemble Track Assembly Generally 2660
How to Disassemble Full Track Shoes Assembly 2660
How to Assemble Full Track Shoes Assembly 2663
Disassemble and Assemble One Track Link Assembly in Field 2677
How to Disassemble One Track Link Assembly in Field 2678
How to Assemble One Track Link Assembly in Field 2680
Disassemble and Assemble Master Link 2682
How to Disassemble Master Link 2684
How to Assemble Master Link 2684
Remove and Install Equalizer Bar Assembly 2687
How to Remove Equalizer Bar Assembly 2687
How to Install Equalizer Bar Assembly 2692
Disassemble and Assemble Equalizer Bar Bushing 2697
How to Disassemble Equalizer Bar Bushing 2697
How to Assemble Equalizer Bar Bushing 2698
Remove and Install Segment Teeth 2700
How to Remove Segment Teeth 2700
How to Install Segment Teeth 2700
Remove and Install Power Ladder Assembly 2702
How to Remove Power Ladder Assembly 2702
How to Install Power Ladder Assembly 2705
Open and Close Underguard Assembly 2708
How to Open Underguard Assembly 2708
How to Close Underguard Assembly 2714
Remove and Install Under Guard Assembly 2720
How to Remove Underguard Assembly 2720
How to Install Underguard Assembly 2727
Hydraulic System 2733
Remove and Install Hydraulic Tank Assembly 2733
How to Remove Hydraulic Tank Assembly 2733
How to Install Hydraulic Tank Assembly 2737
Remove and Install Work Equipment Pump Assembly 2742
How to Remove Work Equipment Pump Assembly 2742
How to Install Work Equipment Pump Assembly 2746
Remove and Install Power Train Pump and Steering Lubrication Pump Assembly 2751
How to Remove Power Train Pump and Steering Lubrication Pump Assembly 2751
How to Install Power Train Pump and Steering Lubrication Pump Assembly 2751
Remove and Install Cooling Fan Pump Assembly 2753
How to Remove Cooling Fan Pump Assembly 2753
How to Install Cooling Fan Pump Assembly 2754
Remove and Install Scavenging Pump Assembly 2756
How to Remove Scavenging Pump Assembly 2756
How to Install Scavenging Pump Assembly 2756
Disassemble and Assemble Control Valve Assembly 2758
How to Assemble Control Valve Assembly 2758
Remove and Install Control Valve Assembly 2761
How to Remove Control Valve Assembly 2761
How to Install Control Valve Assembly 2767
Work Equipment 2774
Remove and Install Blade Assembly 2774
How to Remove Blade Assembly 2774
How to Install Blade Assembly 2777
Remove and Install Blade Lift Cylinder Assembly 2781
How to Remove Blade Lift Cylinder Assembly 2782
How to Install Blade Lift Cylinder Assembly 2787
Disassemble and Assemble Blade Assembly 2792
How to Disassemble Blade Assembly 2792
How to Assemble Blade Assembly 2795
Disassemble and Assemble Giant Ripper Assembly 2799
How to Disassemble Giant Ripper Assembly 2799
How to Assemble Giant Ripper Assembly 2801
Disassemble and Assemble Blade Lift Cylinder Assembly 2804
How to Disassemble Blade Lift Cylinder Assembly 2804
How to Assemble Blade Lift Cylinder Assembly 2807
Disassemble and Assemble Blade Tilt Cylinder Assembly 2811
How to Disassemble Blade Tilt Cylinder Assembly 2811
How to Assemble Blade Tilt Cylinder Assembly 2813
Disassemble and Assemble Ripper Pin Puller Cylinder Assembly 2816
How to Disassemble Ripper Pin Puller Cylinder Assembly 2816
How to Assemble Ripper Pin Puller Cylinder Assembly 2817
CAB Related Parts 2819
Remove and Install ROPS Guard 2819
How to Remove ROPS Guard 2819
How to Install ROPS Guard 2820
Remove and Install Operator Cab Assembly 2821
How to Remove Operator Cab Assembly 2821
How to Install Operator Cab Assembly 2825
Remove and Install Operator Cab Glass (Adhered Glass) 2829
How to Remove Operator Cab Glass (Adhered Glass) 2830
How to Install Operator Cab Glass (Adhered Glass) 2830
Remove and Install Air Conditioner Unit Assembly 2834
How to Remove Air Conditioner Unit Assembly 2834
How to Install Air Conditioner Unit Assembly 2840
Remove and Install Operator Seat 2846
How to Remove Operator Seat 2846
How to Install Operator Seat 2847
How to Remove and Install Seat Belt 2849
How to Remove Seat Belt 2849
How to Install Seatbelt 2850
Electrical System 2851
Remove and Install Engine Controller Assembly 2851
How to Remove Engine Controller Assembly 2851
How to Install Engine Controller Assembly 2855
Remove and Install Power Train Controller Assembly 2860
How to Remove Power Train Controller Assembly 2860
How to Install Power Train Controller Assembly 2861
Remove and Install Work Equipment Controller Assembly 2862
How to Remove Work Equipment Controller Assembly 2862
How to Install Work Equipment Controller Assembly 2863
Remove and Install Machine Monitor Assembly 2864
How to Remove Machine Monitor Assembly 2864
How to Install Machine Monitor Assembly 2865
Remove and Install Mass Air Flow and Temperature Sensor 2867
How to Remove Mass Air Flow and Temperature Sensor 2867
How to Install Mass Air Flow and Temperature Sensor 2868
Remove and Install KCCV Crankcase Pressure Sensor 2870
How to Remove KCCV Crankcase Pressure Sensor 2870
How to Install KCCV Crankcase Pressure Sensor 2871
Remove and Install KOMTRAX Terminal Assembly 2872
How to Remove KOMTRAX Terminal Assembly 2872
How to Install KOMTRAX Terminal Assembly 2872
Remove And Install KOMTRAX Plus Controller Assembly 2874
How to Remove KOMTRAX Plus Controller Assembly 2874
How to Install KOMTRAX Plus Controller Assembly 2875
Remove and Install Wireless LAN Unit Assembly 2877
How to Remove Wireless LAN Unit Assembly 2877
How to Install Wireless LAN Unit Assembly 2878
Remove and Install Option Controller Assembly 2880
How to Remove Option Controller Assembly 2880
How to Install Option Controller Assembly 2883
Remove and Install Radio Control Receiver 2888
How to Remove Radio Control Receiver 2888
How to Install Radio Control Receiver 2889
60 Maintenance Standard 2891
Table of Contents 2892
Engine and Cooling System 2893
Maintenance Standard for Engine Mount 2893
Maintenance Standard for Damper 2895
Maintenance Standard for Cooling System 2897
Maintenance Standard for Cooling Fan Pump 2899
Maintenance Standard for Servo Valve 2907
Maintenance Standard for Cooling Fan Motor 2909
Power Train 2912
Maintenance Standard for Universal Joint 2912
Maintenance Standard for Power Train Mount 2913
Maintenance Standard for Torque Converter and PTO 2915
Maintenance Standard for Torque Converter Control Valve 2920
Maintenance Standard for Lockup Clutch ECMV 2922
Maintenance Standard for Stator Clutch ECMV 2923
Maintenance Standard for Transmission 2924
Maintenance Standard for PTO, Transmission Lubrication Pump, and Power Train Pump 2930
Maintenance Standard for Transmission ECMV 2932
Maintenance Standard for Main Relief Valve and Torque Converter Relief Valve 2933
Maintenance Standard for Transmission Lubrication Relief Valve 2934
Maintenance Standard for Transfer, Bevel Gear Shaft, and Steering 2935
Maintenance Standard for Brake Solenoid Valve 2941
Maintenance Standard for Sudden Stop Prevention Valve 2942
Maintenance Standard for Final Drive 2943
Maintenance Standard for Sprocket for Conventional Type Track Shoes 2947
Maintenance Standard for Sprocket Tooth Profile Full-Scale Drawing for Conventional Type Track Shoes 2948
Undercarriage and Frame 2950
Maintenance Standard for Main Frame 2950
Maintenance Standard for Suspension 2953
Maintenance Standard for Track Frame and Idler Cushion 2956
Maintenance Standard for Idler 2960
Maintenance Standard for Track Roller Bogie 2962
Maintenance Standard for Track Roller for Conventional Type Track Shoes 2963
Maintenance Standard for Carrier Roller for Conventional Type Track Shoes 2966
Maintenance Standard for Conventional Type Track Shoes 2967
Maintenance Standard for Single Shoes and Heavy Duty Shoes 2969
Hydraulic System 2970
Maintenance Standard for Hydraulic Tank 2970
Maintenance Standard for Work Equipment Pump 2971
Maintenance Standard for Scavenging Pump 2974
Maintenance Standard for Control Valve 2975
Maintenance Standard for Self-Pressure Reducing Valve 2985
Maintenance Standard for Quick Drop Valve 2988
Work Equipment 2989
Maintenance Standard for Cylinder Stay 2989
Maintenance Standard for Front Work Equipment 2990
Maintenance Standard for Cutting Edge and End Bit 2996
Maintenance Standard for Blade Lift Cylinder 2997
Maintenance Standard for Blade Tilt Cylinder 2999
Maintenance Standard for Variable Multi-Shank Ripper 3001
Maintenance Standard for Variable Giant Ripper 3003
Maintenance Standard for Ripper Lift Cylinder 3005
Maintenance Standard for Ripper Tilt Cylinder 3006
CAB Related Parts 3007
Maintenance Standard for CAB Mount 3007
Maintenance Standard for ROPS 3008
80 Appendix 3009
Table of Contents 3010
Precautions Before Work 3012
Air Conditioner System 3013
Precautions for Refrigerant 3013
Air Conditioner Component 3014
Specifications of Air Conditioner 3016
Structure and Function of Refrigeration Cycle 3017
Outline of Refrigeration Cycle 3018
Component Parts of Air Conditioner System 3020
Air Conditioner Unit 3020
Configuration Diagram of Air Conditioner Unit 3020
Function of Air Conditioner Unit 3022
Component Parts of Air Conditioner Unit 3024
Function of Evaporator as Air Conditioner Unit Component 3025
Function of Heater Core as Air Conditioner Unit Component 3025
Function of Evaporator Temperature Sensor as Air Conditioner Unit Component 3025
Function of Servo Motor as Air Conditioner Unit Component 3025
Structure of Expansion Valve as Air Conditioner Unit Component 3026
Function of Expansion Valve as Air Conditioner Unit Component 3026
Operate Expansion Valve as Air Conditioner Unit Component 3026
Function of Triple Pressure Switch 3027
Air Conditioner Controller 3028
Structure of Air Conditioner Controller 3028
Compressor 3029
Structure of Compressor 3029
Specifications of Compressor 3029
Function of Compressor 3029
Condenser 3030
Structure of Condenser 3030
Specifications of Condenser 3030
Function of Condenser 3030
Receiver Drier 3031
Structure of Receiver Dryer 3031
Specifications of Receiver Dryer 3031
Function of Receiver Dryer 3031
Air Conditioner Related Sensors 3032
Structure of Sunlight Sensor 3032
Function of Sunlight Sensor 3032
Structure of Outside Temperature Sensor 3032
Function of Outside Air Temperature Sensor 3032
Explanation of Procedure for Test of and Troubleshooting of Air Conditioner 3034
Circuit Diagram and Configuration of Connector Pins of Air Conditioner 3036
System Diagram of Air Conditioner 3038
Input and Output Signals of Air Conditioner Controller 3039
Function of Air Conditioner Controller 3040
Locations of Air Conditioner Parts and Layout of Connectors 3041
Examine Air Leakage (Duct) 3050
How to Examine Air Leakage (Duct) 3050
Examine Air Conditioner with Self-Diagnosis Function 3053
Open the Electrical System Abnormality Record Screen in Service Mode of Machine Monitor 3054
Examine Vent (Mode) Changeover 3055
How to Examine Vent (Mode) Changeover 3055
Examine Fresh/Recirc Air Changeover 3056
How to Examine Fresh/Recirc Air Changeover 3056
Examine Sunlight Sensor 3057
How to Examine Sunlight Sensor 3057
Examine Refrigerant (Triple) Pressure Switch 3058
How to Examine Refrigerant (Triple) Pressure Switch 3058
Examine Relay 3059
How to Examine Relay 3059
Air Conditioner Troubleshooting Chart 1 3060
Air Conditioner Troubleshooting Chart 2 3061
Information Shown in Troubleshooting Table 3064
Failure Code [879AKA] 3065
Failure Code [879AKB] 3066
Failure Code [879BKA] 3067
Failure Code [879BKB] 3069
Failure Code [879CKA] 3071
Failure Code [879CKB] 3072
Failure Code [879DKZ] 3073
Failure Code [879EMC] 3075
Failure Code [879FMC] 3076
Failure Code [879GKX] 3077
A-1 Troubleshooting for Power Supply System (Air Conditioner Does Not Operate) 3079
A-2 Troubleshooting for Compressor and Refrigerant System (Air is Not Cooled) 3081
A-3 Troubleshooting for Blower Motor System (No Air Comes Out or Air Flow is Abnormal) 3085
A-4 Troubleshooting for Fresh/Recirc Air Changeover 3087
Troubleshooting by Gauge Pressure 3089
Connect Service Tool 3092
How to Connect Service Tool 3092
Precautions for Disconnection and Connection of Air Conditioner Piping 3094
Handle Compressor Oil 3096
90 Circuit Diagrams 3099
Table of Contents 3100
Hydraulic Circuit Diagram 3101
Symbols Used in Hydraulic Circuit Diagram 3101
Hydraulic Circuit Diagram 3105
Power Train Hydraulic Circuit Diagram 3107
Electrical Circuit Diagram 3109
Symbols Used in Electric Circuit Diagram 3109
Electrical Circuit Diagram (1/12) 3113
Electrical Circuit Diagram (2/12) 3115
Electrical Circuit Diagram (3/12) 3117
Electrical Circuit Diagram (4/12) 3119
Electrical Circuit Diagram (5/12) 3121
Electrical Circuit Diagram (6/12) 3123
Electrical Circuit Diagram (7/12) 3125
Electrical Circuit Diagram (8/12) 3127
Electrical Circuit Diagram (9/12) 3129
Electrical Circuit Diagram (10/12) 3131
Electrical Circuit Diagram (11/12) 3133
Electrical Circuit Diagram (12/12) 3135
Electrical Circuit Diagram of Inside of CAB (1/13) 3137
Electrical Circuit Diagram of Inside of CAB (2/13) 3139
Electrical Circuit Diagram of Inside of CAB (3/13) 3141
Electrical Circuit Diagram of Inside of CAB (4/13) 3143
Electrical Circuit Diagram of Inside of CAB (5/13) 3145
Electrical Circuit Diagram of Inside of CAB (6/13) 3147
Electrical Circuit Diagram of Inside of CAB (7/13) 3149
Electrical Circuit Diagram of Inside of CAB (8/13) 3151
Electrical Circuit Diagram of Inside of CAB (9/13) 3153
Electrical Circuit Diagram of Inside of CAB (10/13) 3155
Electrical Circuit Diagram of Inside of CAB (11/13) 3157
Electrical Circuit Diagram of Inside of CAB (12/13) 3159
Electrical Circuit Diagram of Inside of CAB (13/13) 3161
Index 3163

DESCRIPTION:

Komatsu D375A-8 Bulldozer Shop Manual SEN06729-04 – 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