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Komatsu d375 a 6r dozer bulldozer service repair manual sn 65001 and up

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BULLDOZER SEN05214-02 D375A-6R SERIAL NUMBERS 65001 and up
D375A-6R SEN0521402-00 00-1 D375A-6R Shop Manual 00-1 BULLDOZER D375A-6R Machine model Serial number D375A-6R 65001 and up 00 Index and foreword 00-1 00-1
Shop Manual Table of contents D375A-6R Table of contents 00-2 Notice of revision .................................................................................................................... 1 00 Index and Foreword Table of contents .................................................................................................................... 00 - 2 Table of contents ................................................................................................................. 00 - 2 Foreword and general information.......................................................................................... 00 - 5 Safety notice ........................................................................................................................ 00 - 5 How to read the shop manual.............................................................................................. 00 - 10 Explanation of terms for maintenance standard .................................................................. 00 - 12 Handling of electric equipment and hydraulic components.................................................. 00 - 14 Handling of connectors newly used for engines .................................................................. 00 - 23 How to read electric wire code............................................................................................. 00 - 26 Precautions when carrying out work.................................................................................... 00 - 29 Method of disassembling and connecting push-pull type coupler........................................ 00 - 32 Standard tightening torque table.......................................................................................... 00 - 35 List of Abbreviation .............................................................................................................. 00 - 39 Conversion table.................................................................................................................. 00 - 43 01 Specification Specification and technical data ............................................................................................. 01 - 3 Specification drawing........................................................................................................... 01 - 3 Specifications....................................................................................................................... 01 - 4 Weight table......................................................................................................................... 01 - 9 Table of fuel, coolant and lubricants .................................................................................... 01 - 11 10 Structure and function Engine and cooling system ..................................................................................................... 10- 4 Cooling system .................................................................................................................... 10- 4 Cooling fan pump................................................................................................................. 10- 7 Cooling fan motor................................................................................................................. 10- 28 Power train.............................................................................................................................. 10- 34 Power train........................................................................................................................... 10- 34 Overall drawing of power train unit ...................................................................................... 10- 36 Power train hydraulic equipment arrangement drawing....................................................... 10- 38 Damper and universal joint .................................................................................................. 10- 40 Torque converter and PTO .................................................................................................. 10- 42 Torque converter control valve ............................................................................................ 10- 48 Main relief valve and torque converter relief valve............................................................... 10- 50 Lockup clutch ECMV and stator clutch ECMV..................................................................... 10- 52 Scavenging pump ................................................................................................................ 10- 57 Transmission control............................................................................................................ 10- 58 PCCS lever .......................................................................................................................... 10- 60 Transmission........................................................................................................................ 10- 64 Transmission ECMV ............................................................................................................ 10- 78 Transmission lubrication relief valve.................................................................................... 10- 83 Steering and brake control................................................................................................... 10- 84 Transfer unit, bevel gear shaft and steering ........................................................................ 10- 86 Steering control valve .......................................................................................................... 10- 92 Steering clutch ECMV and Steering brake ECMV............................................................... 10- 94 Parking brake valve ............................................................................................................. 10- 102 Sudden stop prevention valve.............................................................................................. 10- 103 00-2 (01)
Shop Manual Table of contents D375A-6R Final drive ............................................................................................................................ 10- 105 Undercarriage and frame........................................................................................................ 10- 110 Track frame.......................................................................................................................... 10- 110 Idler cushion ........................................................................................................................ 10- 112 Track roller bogie................................................................................................................. 10- 113 Main frame........................................................................................................................... 10- 114 Suspension.......................................................................................................................... 10- 116 Hydraulic system .................................................................................................................... 10- 119 Work equipment hydraulic piping diagram........................................................................... 10- 119 PPC control piping diagram................................................................................................. 10- 123 Work equipment control....................................................................................................... 10- 124 Hydraulic tank...................................................................................................................... 10- 126 Accumulator......................................................................................................................... 10- 128 PPC lock valve..................................................................................................................... 10- 129 PPC valve............................................................................................................................ 10- 130 Piston valve ......................................................................................................................... 10- 142 Quick drop valve.................................................................................................................. 10- 143 Pin puller switch................................................................................................................... 10- 145 Pin puller solenoid valve...................................................................................................... 10- 146 Blade control lever (only for the machine with dual tilt specification)................................... 10- 148 Work equipment pump......................................................................................................... 10- 150 Control valve........................................................................................................................ 10- 162 Self-pressure reducing valve ............................................................................................... 10- 187 Work equipment...................................................................................................................... 10- 194 Cylinder stay ........................................................................................................................ 10- 194 Cab ......................................................................................................................................... 10- 195 Cab mount ........................................................................................................................... 10- 195 Cab ...................................................................................................................................... 10- 196 Electrical system..................................................................................................................... 10- 198 Engine control...................................................................................................................... 10- 198 Engine control system ......................................................................................................... 10- 199 CRI engine control system................................................................................................... 10- 208 Monitor system .................................................................................................................... 10- 210 Machine monitor .................................................................................................................. 10- 212 Lamp system ....................................................................................................................... 10- 230 Engine preheat (electrical intake air heater) control ............................................................ 10- 231 Palm command control system............................................................................................ 10- 232 Sensor ................................................................................................................................. 10- 235 Vehicle health monitoring system (VHMS) .......................................................................... 10- 241 ORBCOMM system ............................................................................................................. 10- 247 20 Standard value table Standard service value table .................................................................................................. 20- 3 Standard value table for engine........................................................................................... 20- 3 Standard value table for machine........................................................................................ 20- 4 30 Testing and adjusting Tools for testing, adjusting and troubleshooting ..................................................................... 30- 4 Diagnosis equipment list...................................................................................................... 30- 4 Engine and cooling system..................................................................................................... 30- 6 Testing engine speed .......................................................................................................... 30- 6 Testing intake air pressure (boost pressure) ....................................................................... 30- 9 Testing exhaust temperature............................................................................................... 30- 11 Testing exhaust gas color.................................................................................................... 30- 14 (01) 00-3
Shop Manual Table of contents D375A-6R Adjusting valve clearance .................................................................................................... 30- 16 Measuring compression pressure........................................................................................ 30- 18 Testing blow-by pressure..................................................................................................... 30- 21 Testing engine oil pressure.................................................................................................. 30- 23 Handling of fuel system devices .......................................................................................... 30- 24 Releasing residual pressure from fuel system..................................................................... 30- 25 Testing fuel pressure ........................................................................................................... 30- 26 Handling of reduced cylinder mode operation ..................................................................... 30- 27 Handling of no injection cranking operation......................................................................... 30- 28 Testing leakage from pressure limiter and return rate from injector .................................... 30- 29 Bleeding air from fuel circuit................................................................................................. 30- 32 Testing fuel circuit for leakage ............................................................................................. 30- 34 Replacing and adjusting alternator and air conditioner compressor belt ............................. 30- 35 Measuring fan speed ........................................................................................................... 30- 36 Testing fan circuit oil pressure ............................................................................................. 30- 37 Bleeding air from fan pump.................................................................................................. 30- 38 Adjusting fuel control dial and decelerator pedal ................................................................. 30- 39 Power train.............................................................................................................................. 30- 42 Testing power train oil pressure........................................................................................... 30- 42 Adjusting transmission output speed sensor ....................................................................... 30- 56 Simple test procedure for brake performance...................................................................... 30- 57 Adjusting brake pedal and parking brake lever.................................................................... 30- 58 Adjusting position of pccs lever console .............................................................................. 30- 61 Emergency escape method when there is failure in power train ......................................... 30- 62 Undercarriage and frame ........................................................................................................ 30- 64 Inspecting wear of sprocket ................................................................................................. 30- 64 Testing and adjusting track shoe tension............................................................................. 30- 65 Hydraulic system..................................................................................................................... 30- 66 Testing and adjusting work equipment oil pressure............................................................. 30- 66 Testing control circuit main pressure ................................................................................... 30- 69 Testing PPC valve output pressure ..................................................................................... 30- 70 Adjusting play of PPC valve................................................................................................. 30- 72 Testing output pressure of ripper pin-puller solenoid valve ................................................. 30- 73 Checking location of cause of hydraulic drift of blade and ripper......................................... 30- 74 Testing leakage inside work equipment cylinder ................................................................. 30- 75 Releasing remaining pressure in work equipment cylinders................................................ 30- 76 Bleeding air from work equipment cylinders ........................................................................ 30- 77 Adjusting ripper lever position.............................................................................................. 30- 78 Work equipment...................................................................................................................... 30- 80 Adjusting work equipment lock lever.................................................................................... 30- 80 Adjusting blade .................................................................................................................... 30- 81 Cab and its attachments ......................................................................................................... 30- 84 Testing and adjusting operator's cab ................................................................................... 30- 84 Electrical system ..................................................................................................................... 30- 90 Special functions of machine monitor (EMMS).................................................................... 30- 90 Handling of voltage circuit of engine controller .................................................................... 30- 148 Adjustment method when controller has been replaced...................................................... 30- 149 Preparation work for troubleshooting for electrical equipment system ................................ 30- 153 Inspection procedure of diode.............................................................................................. 30- 157 Handling of optional devices................................................................................................ 30- 158 Request for opening ORBCOMM terminal........................................................................... 30- 159 Initialization procedures for VHMS controller....................................................................... 30- 161 Using method of KOMTRAX functions of ORBCOMM terminal........................................... 30- 175 Precautions for replacing VHMS controller.......................................................................... 30- 178 00-3-1 (01)
Shop Manual Table of contents D375A-6R Pm Clinic................................................................................................................................. 30- 184 Pm Clinic service ................................................................................................................. 30- 184 40 Troubleshooting General information on troubleshooting.................................................................................. 40- 10 Points to remember when troubleshooting .......................................................................... 40- 10 Sequence of events in troubleshooting................................................................................ 40- 11 Checks before troubleshooting............................................................................................ 40- 12 Classification and procedures for troubleshooting............................................................... 40- 37 Failure codes table .............................................................................................................. 40- 40 Classification and procedures for troubleshooting numbers................................................ 40- 50 Information in troubleshooting table..................................................................................... 40- 52 Troubleshooting method for disconnecting wiring harness of pressure sensor system ...... 40- 54 Connection table for connector pin numbers ....................................................................... 40- 57 T-branch box and T-branch adapter table ........................................................................... 40- 93 Connector list and layout ..................................................................................................... 40- 96 Fuse locations table............................................................................................................. 40- 110 Troubleshooting by failurecode............................................................................................... 40- 114 Failure code [1380MW] Lock up clutch: Slip........................................................................ 40- 114 Failure code [1500L0] Transmission clutch: Abnormal........................................................ 40- 115 Failure code [15E0MW] Transmission clutch: Slip .............................................................. 40- 116 Failure code [15SAL1] Forward clutch: Fill high .................................................................. 40- 118 Failure code [15SALH] Forward clutch: Fill Low.................................................................. 40- 120 Failure code [15SBL1] Reverse clutch: Fill high.................................................................. 40- 122 Failure code [15SBLH] Reverse clutch: Fill Low.................................................................. 40- 124 Failure code [15SEL1] Speed 1st clutch: Fill high ............................................................... 40- 126 Failure code [15SELH] Speed 1st clutch: Fill Low............................................................... 40- 128 Failure code [15SFL1] Speed 2nd clutch: Fill high .............................................................. 40- 130 Failure code [15SFLH] Speed 2nd clutch: Fill Low.............................................................. 40- 132 Failure code [15SGL1] Speed 3rd clutch: Fill high .............................................................. 40- 134 Failure code [15SGLH] Speed 3rd clutch: Fill Low .............................................................. 40- 136 Failure code [15SJL1] L/U: Fill high..................................................................................... 40- 138 Failure code [15SJLH] L/U: Fill low...................................................................................... 40- 140 Failure code [1800MW] P/T clutch: Slip............................................................................... 40- 142 Failure code [2201L1] Right clutch: Fill high........................................................................ 40- 144 Failure code [2201LH] Right clutch: Fill low......................................................................... 40- 146 Failure code [2202L1] Left clutch: Fill high .......................................................................... 40- 148 Failure code [2202LH] Left clutch: Fill low........................................................................... 40- 150 Failure code [2300NR] Brake Themal Load Abnormality .................................................... 40- 152 Failure code [2301L1] Right brake: Fill high ........................................................................ 40- 154 Failure code [2301LH] Right brake: Fill low ......................................................................... 40- 156 Failure code [2301NR] Steering Brake RH Themal Load Abnormality................................ 40- 158 Failure code [2302L1] Left brake: Fill high........................................................................... 40- 160 Failure code [2302LH] Left brake: Fill low ........................................................................... 40- 162 Failure code [2302NR] Steering Brake LH Themal Load Abnormality ................................ 40- 164 Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection......................................... 40- 166 Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit ............................................ 40- 168 Failure code [AA10NX] Air Cleaner Clogging...................................................................... 40- 170 Failure code [AB00MA] Battery Charge Abnormal .............................................................. 40- 172 Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 173 Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 174 Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 175 Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 176 Failure code [B@CENS] T/C Oil Overheat.......................................................................... 40- 177 (01) 00-3-2
Shop Manual Table of contents D375A-6R Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 178 Failure code [B@HAZK] Hyd Oil Level Low......................................................................... 40- 179 Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 180 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 182 Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 184 Failure code [CA123] Chg Air Press Sensor Low Error....................................................... 40- 186 Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 188 Failure code [CA132] Throttle Sensor Low Error................................................................. 40- 190 Failure code [CA135] Eng Oil Press Sensor High Error ...................................................... 40- 192 Failure code [CA141] Eng Oil Press Sensor Low Error ....................................................... 40- 194 Failure code [CA144] Coolant Temp Sens High Error......................................................... 40- 196 Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 198 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 200 Failure code [CA154] Chg Air Temp Sensor Low Error....................................................... 40- 202 Failure code [CA187] Sens Supply 2 Volt Low Error ........................................................... 40- 204 Failure code [CA212] Eng Oil Temp Sensor High Error ...................................................... 40- 206 Failure code [CA213] Eng Oil Temp Sensor Low Error ....................................................... 40- 208 Failure code [CA221] Ambient Press Sens High Error ........................................................ 40- 210 Failure code [CA222] Ambient Press Sens Low Error......................................................... 40- 212 Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 214 Failure code [CA234] Eng Overspeed ................................................................................. 40- 215 Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 216 Failure code [CA263] Fuel Temp Sensor High Error ........................................................... 40- 218 Failure code [CA265] Fuel Temp Sensor Low Error............................................................ 40- 220 Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 222 Failure code [CA272] IMV/PCV1 Open Error....................................................................... 40- 223 Failure code [CA273] PCV2 Short Error .............................................................................. 40- 224 Failure code [CA274] PCV2 Open Error.............................................................................. 40- 225 Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................ 40- 226 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................ 40- 228 Failure code [CA324] Inj #3 (L#3) Open/Short Error............................................................ 40- 230 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................ 40- 232 Failure code [CA331] Inj #2 (L#2) Open/Short Error............................................................ 40- 234 Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................................ 40- 236 Failure code [CA342] Calibration Code Incompatibility........................................................ 40- 238 Failure code [CA351] Injectors Drive Circuit Error............................................................... 40- 239 Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 240 Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 242 Failure code [CA441] Battery Voltage Low Error................................................................. 40- 243 Failure code [CA442] Battery Voltage High Error ................................................................ 40- 244 Failure code [CA449] Rail Press Very High Error................................................................ 40- 245 Failure code [CA451] Rail Press Sensor High Error............................................................ 40- 246 Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 248 Failure code [CA553] Rail Press High Error ........................................................................ 40- 250 Failure code [CA554] Rail Press Sensor In Range Error..................................................... 40- 251 Failure code [CA559] Rail Press Low Error ......................................................................... 40- 252 Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 256 Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 258 Failure code [CA757] All Continuous Data Lost Error.......................................................... 40- 259 Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 260 Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 262 Failure code [CA2185] Throt Sens Sup Volt High Error....................................................... 40- 263 Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 264 Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 265 00-3-3 (01)
Shop Manual Table of contents D375A-6R Failure code [D110KB] Battery Relay: Drive Short Circuit................................................... 40- 266 Failure code [D130KA] Neutral relay: Disconnection........................................................... 40- 268 Failure code [D130KB] Neutral relay: Short circuit .............................................................. 40- 270 Failure code [D161KA] Back-up alarm releay: Disconnection ............................................. 40- 272 Failure code [D161KB] Back-up alarm releay: Short circuit................................................. 40- 274 Failure code [D182KZ] Preheater Relay Abnormality.......................................................... 40- 276 Failure code [D190KA] ACC signal relay: Disconnection .................................................... 40- 278 Failure code [D190KB] ACC signal relay: Short circuit........................................................ 40- 280 Failure code [D1EFKA] Pre lub. motor relay: Disconnection ............................................... 40- 282 Failure code [D1EFKB] Pre lub. motor relay: Short circuit................................................... 40- 284 Failure code [DAFRKR] Monitor: Can communication lost (PT).......................................... 40- 286 Failure code [dAFRKR] Monitor: CAN communication lost (WE) ........................................ 40- 287 Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 288 Failure code [DB2RKR] ENG cont.: Can communication lost (PT) ..................................... 40- 294 Failure code [dB2RKR] ENG controller: CAN communication lost (WE)............................. 40- 298 Failure code [DB90KT] WE controller: Abnormality in controller ......................................... 40- 299 Failure code [DB91KK] WE controller: Source voltage reduction........................................ 40- 300 Failure code [DB92KK] WE controller: Output voltage reduction ........................................ 40- 302 Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ................................... 40- 304 Failure code [DB99KQ] WE controller: Type select signal .................................................. 40- 306 Failure code [DB9RKR] WE controller: Can communication lost (PT) ................................ 40- 307 Failure code [DBB0KK] VHMS controller:Source voltage reduction.................................... 40- 310 Failure code [DBB0KQ] VHMS connector connection abnormality ..................................... 40- 312 Failure code [DBB3KK] VHMS controller: Source voltage reduction................................... 40- 313 Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction ..................................... 40- 316 Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction ...................................... 40- 318 Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction ...................................... 40- 320 Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) .................................. 40- 322 Failure code [DBE0KT] PT controller: Abnormality in controller .......................................... 40- 323 Failure code [DBE1KK] PT controller: Source voltage reduction......................................... 40- 324 Failure code [DBE2KK] PT controller: Output voltage reduction ......................................... 40- 326 Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction.................................... 40- 328 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction ........................................ 40- 330 Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction ......................................... 40- 332 Failure code [DBE9KQ] PT controller: Type select signal ................................................... 40- 334 Failure code [DBERKR] PT controller: Can communication lost (WE) ................................ 40- 335 Failure code [DD12KA] Shift up Sw: Disconnection ............................................................ 40- 338 Failure code [DD12KB] Shift up Sw: Short circuit................................................................ 40- 340 Failure code [DD13KA] Shift down Sw: Disconnection........................................................ 40- 342 Failure code [DD13KB] Shift down Sw: Short circuit ........................................................... 40- 344 Failure code [DD14KA] Parking lever Sw: Dissconnection.................................................. 40- 346 Failure code [DD14KB] Parking lever Sw: Short circuit ....................................................... 40- 348 Failure code [DDB9L4] Reverse SW Signal disagreement ................................................. 40- 350 Failure code [DDE2KA] Pre lub. oil press sw: Disconnection.............................................. 40- 352 Failure code [DDK3L4] Forward SW Signal disagreement.................................................. 40- 354 Failure code [DDK5KA] Shift switch disconnection ............................................................. 40- 356 Failure code [DDK5KB] Shift switch short circuit ................................................................. 40- 358 Failure code [DDN2LD] Blade tilt RH pressure SW abnormality ......................................... 40- 360 Failure code [DDN3LD] Blade tilt LH pressure SW abnormality.......................................... 40- 362 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection.......................................... 40- 364 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit ............................................. 40- 366 Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection .............................................. 40- 368 Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit.................................................. 40- 370 Failure code [DDNALD] Blade lift up pressure SW abnormality .......................................... 40- 372 (01) 00-3-4
Shop Manual Table of contents D375A-6R Failure code [DDNBLD] Ripper lift up pressure SW abnormality......................................... 40- 374 Failure code [DDNCLD] Ripper lift down pressure SW abnormality.................................... 40- 376 Failure code [DDNDLD] Ripper tilt in pressure SW abnormality.......................................... 40- 378 Failure code [DDNELD] Ripper tilt back pressure SW abnormality ..................................... 40- 380 Failure code [DDNFLD] Blade lift down pressure SW abnormality...................................... 40- 382 Failure code [DDNLKA] Weq lock Sw: Disconnection ......................................................... 40- 384 Failure code [DDNLKB] Weq lock Sw: Short circuit............................................................. 40- 386 Failure code [DDT5KA] Neutral switch disconnection ......................................................... 40- 388 Failure code [DDT5KB] Neutral switch short circuit............................................................. 40- 390 Failure code [DDT5KQ] Lever SPEC selection signal disagreement .................................. 40- 392 Failure code [DDTSL1] S/C: Fill high................................................................................... 40- 394 Failure code [DDTSLH] S/C: Fill low.................................................................................... 40- 396 Failure code [DGE5KX] Ambient temp sensor abnormality................................................. 40- 398 Failure code [DGS1KX] Hyd oil temp: signal abnormal ....................................................... 40- 400 Failure code [DGT1KA] T/C oil temp sensor: Abnormal ...................................................... 40- 402 Failure code [DGT1KX] T/C oil temp sensor: Abnormal ...................................................... 40- 404 Failure code [DGT5KA] F exhaust temp sensor disconnection ........................................... 40- 406 Failure code [DGT5KB] F exhaust temp sensor short circuit............................................... 40- 408 Failure code [DGT6KA] R exhaust temp sensor disconnection........................................... 40- 410 Failure code [DGT6KB] R exhaust temp sensor short circuit .............................................. 40- 412 Failure code [DH21KA] Weq pressure sensor: Disconnection ............................................ 40- 414 Failure code [DH21KB] Weq pressure sensor: Short circuit................................................ 40- 416 Failure code [DHE5KB] ENG blow-by pressure sensor disconnection................................ 40- 418 Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ................................... 40- 420 Failure code [DHT3KX] T/M oil pressure sensor abnormality.............................................. 40- 422 Failure code [DHT5KA] T/C in-pressure sensor: Disconnection.......................................... 40- 424 Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ............................................. 40- 426 Failure code [DHT7KA] T/C out-pressure sensor: Disconnection........................................ 40- 428 Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ........................................... 40- 430 Failure code [DK10KA] Fuel control Dial: Disconnection..................................................... 40- 432 Failure code [DK10KB] Fuel control Dial: Short circuit ........................................................ 40- 434 Failure code [DK30KA] ST lever 1: Disconnection .............................................................. 40- 436 Failure code [DK30KB] ST lever 1: Short circuit.................................................................. 40- 438 Failure code [DK30KX] ST lever: Out of normal range........................................................ 40- 440 Failure code [DK30KZ] ST lever: Disconnection or short circuit.......................................... 40- 441 Failure code [DK30L8] ST lever: Signal mismatch .............................................................. 40- 442 Failure code [DK31KA] ST lever 2: Disconnection .............................................................. 40- 444 Failure code [DK31KB] ST lever 2: Short circuit.................................................................. 40- 446 Failure code [DK40KA] Brake potentiometer: Disconnection .............................................. 40- 448 Failure code [DK40KB] Brake potentiometer: Short circuit.................................................. 40- 450 Failure code [DK55KX] FR lever: Out of normal range........................................................ 40- 452 Failure code [DK55KZ] FR lever: Disconnection or short circuit.......................................... 40- 453 Failure code [DK55L8] FR lever: Signal mismatch .............................................................. 40- 454 Failure code [DK56KA] FR lever 1: Disconnection .............................................................. 40- 456 Failure code [DK56KB] FR lever 1: Short circuit.................................................................. 40- 458 Failure code [DK57KA] FR lever 2: Disconnection .............................................................. 40- 460 Failure code [DK57KB] FR lever 2: Short circuit.................................................................. 40- 462 Failure code [DK60KA] Acceleration sensor: Disconnection ............................................... 40- 464 Failure code [DK60KB] Acceleration sensor: Short circuit................................................... 40- 466 Failure code [DKH1KA] Pitch angle sensor: Disconnection................................................. 40- 468 Failure code [DKH1KB] Pitch angle sensor: Short circuit .................................................... 40- 470 Failure code [DLF1KA] T/C out-speed sensor: Disconnection ............................................ 40- 472 Failure code [DLM3KA] Fan rev. sensor: Disconnection ..................................................... 40- 474 Failure code [DLM3MB] Fan control: Decline ...................................................................... 40- 476 00-3-5 (01)
Shop Manual Table of contents D375A-6R Failure code [DLT3KA] T/M out-speed sensor: Disconnection............................................ 40- 477 Failure code [DLT3KB] T/M out-speed sensor: Abnormal ................................................... 40- 478 Failure code [DW59KA] Blade dual selector SOL disconnection ........................................ 40- 479 Failure code [DW59KB] Blade dual selector SOL short circuit ............................................ 40- 480 Failure code [DW59KY] Blade dual selector SOL hot short ................................................ 40- 482 Failure code [DW5AKA] Blade pitch selector SOL disconnection ....................................... 40- 484 Failure code [DW5AKB] Blade pitch selector SOL short circuit........................................... 40- 485 Failure code [DW5AKY] Blade pitch selector SOL Short circuit .......................................... 40- 486 Failure code [DW7BKA] Fan rev EPC: Disconnection......................................................... 40- 488 Failure code [DW7BKB] Fan rev EPC: Short circuit ............................................................ 40- 489 Failure code [DWN3KA] Ssp solenoid: Disconnection ........................................................ 40- 490 Failure code [DWN3KB] Ssp solenoid: Short circuit ............................................................ 40- 492 Failure code [DWN3KY] SSP solenoid: Short circuit ........................................................... 40- 494 Failure code [DWN5KA] Fan pump solenoid 1: Disconnection ........................................... 40- 496 Failure code [DWN5KB] Fan pump solenoid 1: Short circuit............................................... 40- 498 Failure code [DWN5KY] Fan pump solenoid 1: Short circuit............................................... 40- 500 Failure code [DWNCKA] Fan pump solenoid 2: Disconnection........................................... 40- 502 Failure code [DWNCKB] Fan pump solenoid 2: Short circuit .............................................. 40- 504 Failure code [DWNCKY] Fan pump solenoid 2: Short circuit .............................................. 40- 506 Failure code [DXH1KA] Lock-up ECMV: Disconnection...................................................... 40- 508 Failure code [DXH1KB] Lock-up ECMV: Short circuit ......................................................... 40- 509 Failure code [DXH1KY] Lock-up ECMV: Short circuit ......................................................... 40- 510 Failure code [DXH4KA] 1st clutch ECMV: Disconnection ................................................... 40- 512 Failure code [DXH4KB] 1st clutch ECMV: Short circuit ....................................................... 40- 514 Failure code [DXH4KY] 1st clutch ECMV: Short circuit ....................................................... 40- 516 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection .................................................. 40- 518 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit...................................................... 40- 520 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit...................................................... 40- 522 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ................................................... 40- 524 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit....................................................... 40- 526 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit....................................................... 40- 528 Failure code [DXH7KA] R clutch ECMV: Disconnection...................................................... 40- 530 Failure code [DXH7KB] R clutch ECMV: Short circuit ......................................................... 40- 532 Failure code [DXH7KY] R clutch ECMV: Short circuit ......................................................... 40- 534 Failure code [DXH8KA] F clutch ECMV: Disconnection ...................................................... 40- 536 Failure code [DXH8KB] F clutch ECMV: Short circuit.......................................................... 40- 538 Failure code [DXH8KY] F clutch ECMV: Short circuit.......................................................... 40- 540 Failure code [DXH9KA] Right clutch ECMV: Disconnection................................................ 40- 542 Failure code [DXH9KB] Right clutch ECMV: Short circuit ................................................... 40- 544 Failure code [DXH9KY] Right clutch ECMV: Short circuit ................................................... 40- 546 Failure code [DXHAKA] Left clutch ECMV: Disconnection.................................................. 40- 548 Failure code [DXHAKB] Left clutch ECMV: Short circuit ..................................................... 40- 550 Failure code [DXHAKY] Left clutch ECMV: Short circuit ..................................................... 40- 552 Failure code [DXHBKA] Right brake ECMV: Disconnection................................................ 40- 554 Failure code [DXHBKB] Right brake ECMV: Short circuit ................................................... 40- 556 Failure code [DXHBKY] Right brake ECMV: Short circuit ................................................... 40- 558 Failure code [DXHCKA] Left brake ECMV: Disconnection.................................................. 40- 560 Failure code [DXHCKB] Left brake ECMV: Short circuit...................................................... 40- 562 Failure code [DXHCKY] Left brake ECMV: Short circuit...................................................... 40- 564 Failure code [DXJBKA] S/C ECMV: Disconnection ............................................................. 40- 566 Failure code [DXJBKB] S/C ECMV: Short circuit................................................................. 40- 567 Failure code [DXJBKY] S/C ECMV: Short circuit................................................................. 40- 568 Failure code [DY2HKA] Pre lub. motor: Disconnection ....................................................... 40- 570 Failure code [F@BBZL] ENG blow-by pressure high level.................................................. 40- 572 (01) 00-3-6
Shop Manual Table of contents D375A-6R Failure code [F@BYNR] F exhaust temp high level (2)....................................................... 40- 573 Failure code [F@BYNS] F exhaust temp high level (1) ....................................................... 40- 574 Failure code [F@BZNR] R exhaust temp high level (2)....................................................... 40- 575 Failure code [F@BZNS] R exhaust temp high level (1)....................................................... 40- 576 Troubleshooting of electrical system (E-mode)....................................................................... 40- 578 Information contained in troubleshooting table .................................................................... 40- 578 E-1 Engine does not start (starting motor does not turn)..................................................... 40- 580 E-2 Preheater does not operate........................................................................................... 40- 584 E-3 When starting switch is turned ON, machine monitor displays nothing......................... 40- 588 E-4 When starting switch is turned ON (before starting engine), basic check item lights up 40- 592 E-5 Precaution item lights up while engine is running ......................................................... 40- 594 E-6 Emergency stop item lights up while engine is running................................................. 40- 596 E-7 Engine coolant temperature gauge does not indicate normally .................................... 40- 597 E-8 Fuel gauge does not indicate properly .......................................................................... 40- 598 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ............... 40- 600 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally..................... 40- 601 E-11 Contents of display by machine monitor are different from applicable machine ......... 40- 602 E-12 Machine monitor does not display some items ........................................................... 40- 602 E-13 Function switch does not work .................................................................................... 40- 602 E-14 Operation mode does not change............................................................................... 40- 603 E-15 Gearshift mode does not change ................................................................................ 40- 603 E-16 Customize function does not operate normally ........................................................... 40- 604 E-17 Customize memory function does not operate normally ............................................. 40- 604 E-18 Alarm buzzer does not sound or does not stop........................................................... 40- 605 E-19 When starting switch is turned OFF, service meter is not displayed........................... 40- 605 E-20 Machine monitor cannot be set in service mode......................................................... 40- 605 E-21 The ripper pin puller cylinder does not operate........................................................... 40- 606 E-22 Horn does not sound or does not stop ........................................................................ 40- 608 E-23 Back-up alarm does not sound or does not stop......................................................... 40- 610 E-24 Fan does not reverse .................................................................................................. 40- 612 E-25 The head lamp and rear lamp do not light up.............................................................. 40- 613 E-26 Windshield wiper does not operate ............................................................................. 40- 622 E-27 Window washer does not operate............................................................................... 40- 630 E-28 Electric priming pump does not operate or does not stop automatically..................... 40- 638 E-29 Orbcomm terminal does not operate normally (Data are not transmitted) .................. 40- 640 E-30 Gear cannot be shifted................................................................................................ 40- 642 Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 644 Information in troubleshooting table..................................................................................... 40- 644 List of Failure Modes and Causes ....................................................................................... 40- 646 H-1 Machine lacks power(or drawbar pull) .......................................................................... 40- 648 H-2 Machine cannot travel (at 2nd or 3rd each speed)........................................................ 40- 650 H-3 Machine cannot travel at any gear speeds ................................................................... 40- 651 H-4 Machine travels only in one direction, forward or reverse............................................. 40- 653 H-5 Large time lag at gear shifting or directional change .................................................... 40- 654 H-6 Machine connot turn...................................................................................................... 40- 655 H-7 Machine turns only to one side ..................................................................................... 40- 656 H-8 Machine overruns at turnning........................................................................................ 40- 657 H-9 Brake does not work ..................................................................................................... 40- 658 H-10 Torque converter does not lock up.............................................................................. 40- 659 H-11 Power train oil overheats............................................................................................. 40- 660 H-12 All work equipment operates too slow or lacks power ................................................ 40- 661 H-13 All work equipment does not operate.......................................................................... 40- 662 H-14 Blade lift cylinder speed is too slow or lacks power .................................................... 40- 663 H-15 Blade tilt cylinder speed is too slow or lacks power .................................................... 40- 664 00-3-7 (01)
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Shop Manual Table of contents D375A-6R H-16 Ripper lift cylinder speed is too slow or lacks power................................................... 40- 665 H-17 Ripper tilt cylinder speed is too slow or lacks power................................................... 40- 666 H-18 Excessive hydraulic drift of blade lift cylinder.............................................................. 40- 667 H-19 Excessive hydraulic drift of blade tilt cylinder.............................................................. 40- 668 H-20 Excessive hydraulic drift of ripper lift cylinder ............................................................. 40- 669 H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ..................... 40- 670 H-22 Blade pitch does not work (machine with dual tilt specification) ................................. 40- 671 H-23 Abnormal noise from around work equipment pump .................................................. 40- 672 H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)40-673 Troubleshooting of engine (S-mode) ...................................................................................... 40- 674 Method of using troubleshooting chart................................................................................. 40- 674 S-1 Engine does not start easily.......................................................................................... 40- 678 S-2 Engine does not start .................................................................................................... 40- 679 S-3 Engine does not rev up smoothly (response-up is poor)............................................... 40- 682 S-4 Engine stops during operation ...................................................................................... 40- 683 S-5 Engine does not rotate smoothly (hunting) ................................................................... 40- 684 S-6 Engine lacks power (or output shortage) ...................................................................... 40- 685 S-7 Exhaust smoke is black (Incomplete combustion) ........................................................ 40- 686 S-8 Oil is consumption is excessive(or exhaust smoke is blue) .......................................... 40- 687 S-9 Engine oil becomes contaminated quickly .................................................................... 40- 688 S-10 Fuel consumption is excessive ................................................................................... 40- 689 S-11 Oil mixes into coolant(coolant blows back or is reduced) ........................................... 40- 690 S-12 Engine pressure monitor lights up (drop in engine oil pressure)................................. 40- 691 S-13 Oil level rises (Coolant or fuel mixes into oil) .............................................................. 40- 692 S-14 Coolant temperature rises too high (overheating)....................................................... 40- 693 S-15 Abnormal noise is heard ............................................................................................. 40- 694 S-16 Vibration is excessive.................................................................................................. 40- 695 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)............................ 40- 696 50 Disassembly and assembly General information on disassembly and assembly ............................................................... 50- 4 How to read this manual...................................................................................................... 50- 4 Coating materials list ........................................................................................................... 50- 6 Special tool list..................................................................................................................... 50- 9 Sketches of special tools ..................................................................................................... 50- 17 Engine and cooling system..................................................................................................... 50- 25 Removal and installation of fuel supply pump assembly ..................................................... 50- 25 Removal and installation of fuel injector assembly .............................................................. 50- 30 Removal and installation of cylinder head assembly ........................................................... 50- 35 Removal and installation of radiator guard assembly .......................................................... 50- 50 Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)50- 55 Removal and installation of radiator .................................................................................... 50- 60 Removal and installation of hydraulic oil cooler................................................................... 50- 62 Removal and installation of aftercooler................................................................................ 50- 63 Removal and installation of engine assembly...................................................................... 50- 64 Removal and installation of engine hood assembly............................................................. 50- 71 Removal and installation of engine front seal...................................................................... 50- 74 Removal and installation of engine rear seal....................................................................... 50- 76 Removal and installation of fan drive assembly................................................................... 50- 80 Removal and installation of fan motor assembly ................................................................. 50- 82 Removal and installation of fuel tank assembly................................................................... 50- 84 Power train.............................................................................................................................. 50- 86 Removal and installation of damper assembly .................................................................... 50- 86 (01) 00-3-8
Shop Manual Table of contents D375A-6R Disassembly and assembly of damper assembly................................................................ 50- 90 Removal and installation of power train unit assembly........................................................ 50- 93 Disconnection and connection of power train unit assembly ............................................... 50- 99 Disassembly and assembly of PTO assembly..................................................................... 50- 108 Disassembly and assembly of torque converter assembly.................................................. 50- 114 Disassembly and assembly of TORQFLOW transmission assembly .................................. 50- 123 Disassembly and assembly of steering case assembly....................................................... 50- 150 Removal and installation of power train pump and lubrication pump assembly .................. 50- 166 Removal and installation of scavenging pump assembly .................................................... 50- 167 Removal and installation of final drive assembly ................................................................. 50- 168 Disassembly and assembly of final drive assembly............................................................. 50- 170 Undercarriage and frame ........................................................................................................ 50- 183 Removal and installation of track frame assembly............................................................... 50- 183 Removal and installation of idler assembly.......................................................................... 50- 188 Disassembly and assembly of idler assembly ..................................................................... 50- 189 Removal and installation of recoil spring assembly ............................................................. 50- 193 Disassembly and assembly of recoil spring assembly......................................................... 50- 198 Removal and installation of track roller assembly................................................................ 50- 200 Disassembly and assembly of track roller assembly ........................................................... 50- 203 Removal and installation of carrier roller assembly ............................................................. 50- 206 Disassembly and assembly of carrier roller assembly......................................................... 50- 207 Removal and installation of bogie assembly........................................................................ 50- 211 Disassembly and assembly of bogie assembly ................................................................... 50- 216 Removal and installation of first bogie assembly................................................................. 50- 218 Separation and connection of track shoe assembly ............................................................ 50- 223 Overall disassembly and assembly of track shoe................................................................ 50- 227 Link press press-fitting jig dimensions ................................................................................. 50- 244 Disassembly and assembly of one link assembly in the field .............................................. 50- 245 Disassembly and assembly of master link........................................................................... 50- 250 Removal and installation of pivot shaft assembly ................................................................ 50- 254 Removal and installation of equalizer bar............................................................................ 50- 255 Disassembly and assembly of equalizer bar bushing.......................................................... 50- 259 Removal and installation of segment tooth.......................................................................... 50- 261 Hydraulic system..................................................................................................................... 50- 262 Removal and installation of hydraulic tank assembly .......................................................... 50- 262 Removal and installation of work equipment pump assembly ............................................. 50- 265 Removal and installation of fan pump assembly.................................................................. 50- 269 Removal and installation of control valve assembly ............................................................ 50- 271 Disassembly and assembly of control valve assembly........................................................ 50- 273 Disassembly and assembly of blade PPC valve assembly.................................................. 50- 278 Disassembly and assembly of ripper PPC valve assembly ................................................. 50- 281 Disassembly and assembly of hydraulic cylinder assembly ................................................ 50- 283 Disassembly and assembly of ripper pin puller cylinder assembly...................................... 50- 291 Work equipment...................................................................................................................... 50- 294 Removal and installation of blade assembly........................................................................ 50- 294 Disassembly and assembly of blade assembly ................................................................... 50- 296 Disassembly and assembly of giant ripper assembly .......................................................... 50- 300 Cab and its attachments ......................................................................................................... 50- 303 Removal and installation of ROPS guard ............................................................................ 50- 303 Removal and installation of operator's cab assembly.......................................................... 50- 304 Removal and installation of floor frame assembly ............................................................... 50- 308 Removal and installation of air conditioner unit assembly ................................................... 50- 313 00-3-9 (01)
Shop Manual Table of contents D375A-6R Electrical system..................................................................................................................... 50- 319 Removal and installation of transmission controller assembly and steering controller assembly ............................................................................................................................................. 50- 319 Removal and installation of engine controller assembly...................................................... 50- 320 Removal and installation of VHMS controller assembly ...................................................... 50- 322 Removal and installation of machine monitor assembly...................................................... 50- 323 60 Maintenance Standard Engine and cooling system..................................................................................................... 60- 3 Engine mount....................................................................................................................... 60- 3 Cooling fan pump................................................................................................................. 60- 5 Cooling fan motor ................................................................................................................ 60- 12 Power train.............................................................................................................................. 60- 14 Power train unit.................................................................................................................... 60- 14 Damper and universal joint.................................................................................................. 60- 16 Torque converter and PTO.................................................................................................. 60- 19 Main relief valve and torque converter relief valve .............................................................. 60- 22 Lockup clutch ECMV and stator clutch ECMV..................................................................... 60- 23 Scavenging pump................................................................................................................ 60- 24 Transmission control............................................................................................................ 60- 25 Transmission ....................................................................................................................... 60- 26 Transmission lubricating oil relief valve ............................................................................... 60- 31 Power train and lubrication pump ........................................................................................ 60- 32 Transfer, bevel gear shaft and steering unit ........................................................................ 60- 34 Steering control valve .......................................................................................................... 60- 40 Steering clutch ECMV and steering brake ECMV ............................................................... 60- 41 Parking brake valve ............................................................................................................. 60- 42 Final drive ............................................................................................................................ 60- 43 Sprocket............................................................................................................................... 60- 46 Undercarriage and frame........................................................................................................ 60- 48 Track frame.......................................................................................................................... 60- 48 Idler cushion cushion........................................................................................................... 60- 50 Idler...................................................................................................................................... 60- 52 Track roller........................................................................................................................... 60- 54 Carrier roller......................................................................................................................... 60- 56 Track roller bogie................................................................................................................. 60- 57 Track shoe........................................................................................................................... 60- 58 Main frame........................................................................................................................... 60- 62 Suspension.......................................................................................................................... 60- 64 Hydraulic system .................................................................................................................... 60- 68 PPC valve............................................................................................................................ 60- 68 Hydraulic cylinder ................................................................................................................ 60- 74 Quick drop valve.................................................................................................................. 60- 77 Work equipment pump......................................................................................................... 60- 78 Control valve........................................................................................................................ 60- 81 Self-pressure reducing valve ............................................................................................... 60- 94 Work equipment...................................................................................................................... 60- 97 Cylinder stay ........................................................................................................................ 60- 97 Blade.................................................................................................................................... 60- 98 Cutting edge and end bit...................................................................................................... 60- 102 Ripper .................................................................................................................................. 60- 104 80 Appendix Air conditioner......................................................................................................................... 80- 3 (01) 00-3-10
Shop Manual Table of contents D375A-6R Precautions for refrigerant ................................................................................................... 80- 3 Air conditioner component ................................................................................................... 80- 4 Configuration and function of refrigeration cycle.................................................................. 80- 6 Outline of refrigeration cycle ................................................................................................ 80- 7 Air conditioner unit ............................................................................................................... 80- 10 Blower unit ........................................................................................................................... 80- 14 FRESH/RECIRC air changeover damper............................................................................ 80- 15 Compressor ......................................................................................................................... 80- 16 Condenser ........................................................................................................................... 80- 17 Receiver drier....................................................................................................................... 80- 18 Air conditioner control panel ................................................................................................ 80- 20 Procedure for testing and troubleshooting........................................................................... 80- 22 Circuit diagram and arrangement of connector pins............................................................ 80- 24 System diagram................................................................................................................... 80- 26 Parts and connectors layout ................................................................................................ 80- 28 Testing temperature control................................................................................................. 80- 32 Testing FRESH/RECIC air changeover............................................................................... 80- 33 Testing relay ........................................................................................................................ 80- 34 Troubleshooting chart 1 ....................................................................................................... 80- 36 Troubleshooting chart 2 ....................................................................................................... 80- 38 Information in troubleshooting table..................................................................................... 80- 40 Troubleshooting for power supply system (Air conditioner does not operate)..................... 80- 42 Troubleshooting for compressor system (Air is not cooled)................................................. 80- 44 Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) . 80- 48 Troubleshooting for temperature control.............................................................................. 80- 54 Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 56 Troubleshooting with gauge pressure.................................................................................. 80- 58 Connection of service tool.................................................................................................... 80- 60 Precautions for disconnecting and connecting .................................................................... 80- 62 Handling of compressor oil .................................................................................................. 80- 64 90 Diagrams and Drawings Hydraulic diagrams and drawings........................................................................................... 90- 3 Symbols used in hydraulic circuit diagrams......................................................................... 90- 3 Power train hydraulic diagrams and drawings ..................................................................... 90- 5 Hydraulic circuit diagram...................................................................................................... 90- 7 Electrical diagrams and drawings ........................................................................................... 90- 11 Symbols used in electrical circuit diagrams ......................................................................... 90- 11 Electrical circuit diagram...................................................................................................... 90- 15 Index ....................................................................................................................................... 1 00-4 (01)
D375A-6R Forword and general information 00-5 Safety notice 00-5 Important safety notice Appropriate servicing and repair are extremely important to ensure safe operation of the machine.The shop manuals describe the effective and safe servicing and repair methods recommended by Komat- su.Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes. The symbol mark "k" is indicated for matters that require special precautions for such work.The work indicated with the warning mark should be carried out along to the instructions with special at- tention to the precautions.Should a hazardous situation occur or be anticipated during such work, be sure to proceed it safe and take every necessary measure. 1. General precautions k Inappropriate handling creates an ex- treme danger.Read and understand what is described in the Operation and Mainte- nance Manual before operating the ma- chine.Read and understand what is described in this manual before starting work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precau- tions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear the safety glasses when hit- ting parts with a hammer q Always wear safety glasses when grind- ing parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the oper- ator's compartment. 5) Only qualified workers must carry out work and operation which require license or quali- fication. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thor- oughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condi- tion. 9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. (Rev. 2010/02) Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signals Prohibition of operation and handling by unli- censed workers 6 Safety check before starting work Wearing protective goggles(for cleaning or grind- ing work) Wearing shielding goggles and protectors(for welding work) 9 Good physical condition and preparation Precautions against work which you are not used to or you are used to too much 00-5 Forword and general information Safety notice 10 5 7 8

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Komatsu d375 a 6r dozer bulldozer service repair manual sn 65001 and up

  • 2. D375A-6R SEN0521402-00 00-1 D375A-6R Shop Manual 00-1 BULLDOZER D375A-6R Machine model Serial number D375A-6R 65001 and up 00 Index and foreword 00-1 00-1
  • 3. Shop Manual Table of contents D375A-6R Table of contents 00-2 Notice of revision .................................................................................................................... 1 00 Index and Foreword Table of contents .................................................................................................................... 00 - 2 Table of contents ................................................................................................................. 00 - 2 Foreword and general information.......................................................................................... 00 - 5 Safety notice ........................................................................................................................ 00 - 5 How to read the shop manual.............................................................................................. 00 - 10 Explanation of terms for maintenance standard .................................................................. 00 - 12 Handling of electric equipment and hydraulic components.................................................. 00 - 14 Handling of connectors newly used for engines .................................................................. 00 - 23 How to read electric wire code............................................................................................. 00 - 26 Precautions when carrying out work.................................................................................... 00 - 29 Method of disassembling and connecting push-pull type coupler........................................ 00 - 32 Standard tightening torque table.......................................................................................... 00 - 35 List of Abbreviation .............................................................................................................. 00 - 39 Conversion table.................................................................................................................. 00 - 43 01 Specification Specification and technical data ............................................................................................. 01 - 3 Specification drawing........................................................................................................... 01 - 3 Specifications....................................................................................................................... 01 - 4 Weight table......................................................................................................................... 01 - 9 Table of fuel, coolant and lubricants .................................................................................... 01 - 11 10 Structure and function Engine and cooling system ..................................................................................................... 10- 4 Cooling system .................................................................................................................... 10- 4 Cooling fan pump................................................................................................................. 10- 7 Cooling fan motor................................................................................................................. 10- 28 Power train.............................................................................................................................. 10- 34 Power train........................................................................................................................... 10- 34 Overall drawing of power train unit ...................................................................................... 10- 36 Power train hydraulic equipment arrangement drawing....................................................... 10- 38 Damper and universal joint .................................................................................................. 10- 40 Torque converter and PTO .................................................................................................. 10- 42 Torque converter control valve ............................................................................................ 10- 48 Main relief valve and torque converter relief valve............................................................... 10- 50 Lockup clutch ECMV and stator clutch ECMV..................................................................... 10- 52 Scavenging pump ................................................................................................................ 10- 57 Transmission control............................................................................................................ 10- 58 PCCS lever .......................................................................................................................... 10- 60 Transmission........................................................................................................................ 10- 64 Transmission ECMV ............................................................................................................ 10- 78 Transmission lubrication relief valve.................................................................................... 10- 83 Steering and brake control................................................................................................... 10- 84 Transfer unit, bevel gear shaft and steering ........................................................................ 10- 86 Steering control valve .......................................................................................................... 10- 92 Steering clutch ECMV and Steering brake ECMV............................................................... 10- 94 Parking brake valve ............................................................................................................. 10- 102 Sudden stop prevention valve.............................................................................................. 10- 103 00-2 (01)
  • 4. Shop Manual Table of contents D375A-6R Final drive ............................................................................................................................ 10- 105 Undercarriage and frame........................................................................................................ 10- 110 Track frame.......................................................................................................................... 10- 110 Idler cushion ........................................................................................................................ 10- 112 Track roller bogie................................................................................................................. 10- 113 Main frame........................................................................................................................... 10- 114 Suspension.......................................................................................................................... 10- 116 Hydraulic system .................................................................................................................... 10- 119 Work equipment hydraulic piping diagram........................................................................... 10- 119 PPC control piping diagram................................................................................................. 10- 123 Work equipment control....................................................................................................... 10- 124 Hydraulic tank...................................................................................................................... 10- 126 Accumulator......................................................................................................................... 10- 128 PPC lock valve..................................................................................................................... 10- 129 PPC valve............................................................................................................................ 10- 130 Piston valve ......................................................................................................................... 10- 142 Quick drop valve.................................................................................................................. 10- 143 Pin puller switch................................................................................................................... 10- 145 Pin puller solenoid valve...................................................................................................... 10- 146 Blade control lever (only for the machine with dual tilt specification)................................... 10- 148 Work equipment pump......................................................................................................... 10- 150 Control valve........................................................................................................................ 10- 162 Self-pressure reducing valve ............................................................................................... 10- 187 Work equipment...................................................................................................................... 10- 194 Cylinder stay ........................................................................................................................ 10- 194 Cab ......................................................................................................................................... 10- 195 Cab mount ........................................................................................................................... 10- 195 Cab ...................................................................................................................................... 10- 196 Electrical system..................................................................................................................... 10- 198 Engine control...................................................................................................................... 10- 198 Engine control system ......................................................................................................... 10- 199 CRI engine control system................................................................................................... 10- 208 Monitor system .................................................................................................................... 10- 210 Machine monitor .................................................................................................................. 10- 212 Lamp system ....................................................................................................................... 10- 230 Engine preheat (electrical intake air heater) control ............................................................ 10- 231 Palm command control system............................................................................................ 10- 232 Sensor ................................................................................................................................. 10- 235 Vehicle health monitoring system (VHMS) .......................................................................... 10- 241 ORBCOMM system ............................................................................................................. 10- 247 20 Standard value table Standard service value table .................................................................................................. 20- 3 Standard value table for engine........................................................................................... 20- 3 Standard value table for machine........................................................................................ 20- 4 30 Testing and adjusting Tools for testing, adjusting and troubleshooting ..................................................................... 30- 4 Diagnosis equipment list...................................................................................................... 30- 4 Engine and cooling system..................................................................................................... 30- 6 Testing engine speed .......................................................................................................... 30- 6 Testing intake air pressure (boost pressure) ....................................................................... 30- 9 Testing exhaust temperature............................................................................................... 30- 11 Testing exhaust gas color.................................................................................................... 30- 14 (01) 00-3
  • 5. Shop Manual Table of contents D375A-6R Adjusting valve clearance .................................................................................................... 30- 16 Measuring compression pressure........................................................................................ 30- 18 Testing blow-by pressure..................................................................................................... 30- 21 Testing engine oil pressure.................................................................................................. 30- 23 Handling of fuel system devices .......................................................................................... 30- 24 Releasing residual pressure from fuel system..................................................................... 30- 25 Testing fuel pressure ........................................................................................................... 30- 26 Handling of reduced cylinder mode operation ..................................................................... 30- 27 Handling of no injection cranking operation......................................................................... 30- 28 Testing leakage from pressure limiter and return rate from injector .................................... 30- 29 Bleeding air from fuel circuit................................................................................................. 30- 32 Testing fuel circuit for leakage ............................................................................................. 30- 34 Replacing and adjusting alternator and air conditioner compressor belt ............................. 30- 35 Measuring fan speed ........................................................................................................... 30- 36 Testing fan circuit oil pressure ............................................................................................. 30- 37 Bleeding air from fan pump.................................................................................................. 30- 38 Adjusting fuel control dial and decelerator pedal ................................................................. 30- 39 Power train.............................................................................................................................. 30- 42 Testing power train oil pressure........................................................................................... 30- 42 Adjusting transmission output speed sensor ....................................................................... 30- 56 Simple test procedure for brake performance...................................................................... 30- 57 Adjusting brake pedal and parking brake lever.................................................................... 30- 58 Adjusting position of pccs lever console .............................................................................. 30- 61 Emergency escape method when there is failure in power train ......................................... 30- 62 Undercarriage and frame ........................................................................................................ 30- 64 Inspecting wear of sprocket ................................................................................................. 30- 64 Testing and adjusting track shoe tension............................................................................. 30- 65 Hydraulic system..................................................................................................................... 30- 66 Testing and adjusting work equipment oil pressure............................................................. 30- 66 Testing control circuit main pressure ................................................................................... 30- 69 Testing PPC valve output pressure ..................................................................................... 30- 70 Adjusting play of PPC valve................................................................................................. 30- 72 Testing output pressure of ripper pin-puller solenoid valve ................................................. 30- 73 Checking location of cause of hydraulic drift of blade and ripper......................................... 30- 74 Testing leakage inside work equipment cylinder ................................................................. 30- 75 Releasing remaining pressure in work equipment cylinders................................................ 30- 76 Bleeding air from work equipment cylinders ........................................................................ 30- 77 Adjusting ripper lever position.............................................................................................. 30- 78 Work equipment...................................................................................................................... 30- 80 Adjusting work equipment lock lever.................................................................................... 30- 80 Adjusting blade .................................................................................................................... 30- 81 Cab and its attachments ......................................................................................................... 30- 84 Testing and adjusting operator's cab ................................................................................... 30- 84 Electrical system ..................................................................................................................... 30- 90 Special functions of machine monitor (EMMS).................................................................... 30- 90 Handling of voltage circuit of engine controller .................................................................... 30- 148 Adjustment method when controller has been replaced...................................................... 30- 149 Preparation work for troubleshooting for electrical equipment system ................................ 30- 153 Inspection procedure of diode.............................................................................................. 30- 157 Handling of optional devices................................................................................................ 30- 158 Request for opening ORBCOMM terminal........................................................................... 30- 159 Initialization procedures for VHMS controller....................................................................... 30- 161 Using method of KOMTRAX functions of ORBCOMM terminal........................................... 30- 175 Precautions for replacing VHMS controller.......................................................................... 30- 178 00-3-1 (01)
  • 6. Shop Manual Table of contents D375A-6R Pm Clinic................................................................................................................................. 30- 184 Pm Clinic service ................................................................................................................. 30- 184 40 Troubleshooting General information on troubleshooting.................................................................................. 40- 10 Points to remember when troubleshooting .......................................................................... 40- 10 Sequence of events in troubleshooting................................................................................ 40- 11 Checks before troubleshooting............................................................................................ 40- 12 Classification and procedures for troubleshooting............................................................... 40- 37 Failure codes table .............................................................................................................. 40- 40 Classification and procedures for troubleshooting numbers................................................ 40- 50 Information in troubleshooting table..................................................................................... 40- 52 Troubleshooting method for disconnecting wiring harness of pressure sensor system ...... 40- 54 Connection table for connector pin numbers ....................................................................... 40- 57 T-branch box and T-branch adapter table ........................................................................... 40- 93 Connector list and layout ..................................................................................................... 40- 96 Fuse locations table............................................................................................................. 40- 110 Troubleshooting by failurecode............................................................................................... 40- 114 Failure code [1380MW] Lock up clutch: Slip........................................................................ 40- 114 Failure code [1500L0] Transmission clutch: Abnormal........................................................ 40- 115 Failure code [15E0MW] Transmission clutch: Slip .............................................................. 40- 116 Failure code [15SAL1] Forward clutch: Fill high .................................................................. 40- 118 Failure code [15SALH] Forward clutch: Fill Low.................................................................. 40- 120 Failure code [15SBL1] Reverse clutch: Fill high.................................................................. 40- 122 Failure code [15SBLH] Reverse clutch: Fill Low.................................................................. 40- 124 Failure code [15SEL1] Speed 1st clutch: Fill high ............................................................... 40- 126 Failure code [15SELH] Speed 1st clutch: Fill Low............................................................... 40- 128 Failure code [15SFL1] Speed 2nd clutch: Fill high .............................................................. 40- 130 Failure code [15SFLH] Speed 2nd clutch: Fill Low.............................................................. 40- 132 Failure code [15SGL1] Speed 3rd clutch: Fill high .............................................................. 40- 134 Failure code [15SGLH] Speed 3rd clutch: Fill Low .............................................................. 40- 136 Failure code [15SJL1] L/U: Fill high..................................................................................... 40- 138 Failure code [15SJLH] L/U: Fill low...................................................................................... 40- 140 Failure code [1800MW] P/T clutch: Slip............................................................................... 40- 142 Failure code [2201L1] Right clutch: Fill high........................................................................ 40- 144 Failure code [2201LH] Right clutch: Fill low......................................................................... 40- 146 Failure code [2202L1] Left clutch: Fill high .......................................................................... 40- 148 Failure code [2202LH] Left clutch: Fill low........................................................................... 40- 150 Failure code [2300NR] Brake Themal Load Abnormality .................................................... 40- 152 Failure code [2301L1] Right brake: Fill high ........................................................................ 40- 154 Failure code [2301LH] Right brake: Fill low ......................................................................... 40- 156 Failure code [2301NR] Steering Brake RH Themal Load Abnormality................................ 40- 158 Failure code [2302L1] Left brake: Fill high........................................................................... 40- 160 Failure code [2302LH] Left brake: Fill low ........................................................................... 40- 162 Failure code [2302NR] Steering Brake LH Themal Load Abnormality ................................ 40- 164 Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection......................................... 40- 166 Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit ............................................ 40- 168 Failure code [AA10NX] Air Cleaner Clogging...................................................................... 40- 170 Failure code [AB00MA] Battery Charge Abnormal .............................................................. 40- 172 Failure code [B@BAZG] Eng Oil Press Low........................................................................ 40- 173 Failure code [B@BAZK] Eng Oil Level Low......................................................................... 40- 174 Failure code [B@BCNS] Eng Water Overheat .................................................................... 40- 175 Failure code [B@BCZK] Eng Water Level Low ................................................................... 40- 176 Failure code [B@CENS] T/C Oil Overheat.......................................................................... 40- 177 (01) 00-3-2
  • 7. Shop Manual Table of contents D375A-6R Failure code [B@HANS] Hyd Oil Overheat.......................................................................... 40- 178 Failure code [B@HAZK] Hyd Oil Level Low......................................................................... 40- 179 Failure code [CA111] ECM Critical Internal Failure ............................................................. 40- 180 Failure code [CA115] Eng Ne and Bkup Speed Sens Error ................................................ 40- 182 Failure code [CA122] Chg Air Press Sensor High Error ...................................................... 40- 184 Failure code [CA123] Chg Air Press Sensor Low Error....................................................... 40- 186 Failure code [CA131] Throttle Sensor High Error ................................................................ 40- 188 Failure code [CA132] Throttle Sensor Low Error................................................................. 40- 190 Failure code [CA135] Eng Oil Press Sensor High Error ...................................................... 40- 192 Failure code [CA141] Eng Oil Press Sensor Low Error ....................................................... 40- 194 Failure code [CA144] Coolant Temp Sens High Error......................................................... 40- 196 Failure code [CA145] Coolant Temp Sens Low Error.......................................................... 40- 198 Failure code [CA153] Chg Air Temp Sensor High Error ...................................................... 40- 200 Failure code [CA154] Chg Air Temp Sensor Low Error....................................................... 40- 202 Failure code [CA187] Sens Supply 2 Volt Low Error ........................................................... 40- 204 Failure code [CA212] Eng Oil Temp Sensor High Error ...................................................... 40- 206 Failure code [CA213] Eng Oil Temp Sensor Low Error ....................................................... 40- 208 Failure code [CA221] Ambient Press Sens High Error ........................................................ 40- 210 Failure code [CA222] Ambient Press Sens Low Error......................................................... 40- 212 Failure code [CA227] Sens Supply 2 Volt High Error .......................................................... 40- 214 Failure code [CA234] Eng Overspeed ................................................................................. 40- 215 Failure code [CA238] Ne Speed Sens Supply Volt Error..................................................... 40- 216 Failure code [CA263] Fuel Temp Sensor High Error ........................................................... 40- 218 Failure code [CA265] Fuel Temp Sensor Low Error............................................................ 40- 220 Failure code [CA271] IMV/PCV1 Short Error....................................................................... 40- 222 Failure code [CA272] IMV/PCV1 Open Error....................................................................... 40- 223 Failure code [CA273] PCV2 Short Error .............................................................................. 40- 224 Failure code [CA274] PCV2 Open Error.............................................................................. 40- 225 Failure code [CA322] Inj #1 (L#1) Open/Short Error............................................................ 40- 226 Failure code [CA323] Inj #5 (L#5) Open/Short Error............................................................ 40- 228 Failure code [CA324] Inj #3 (L#3) Open/Short Error............................................................ 40- 230 Failure code [CA325] Inj #6 (L#6) Open/Short Error............................................................ 40- 232 Failure code [CA331] Inj #2 (L#2) Open/Short Error............................................................ 40- 234 Failure code [CA332] Inj #4 (L#4) Open/Short Error............................................................ 40- 236 Failure code [CA342] Calibration Code Incompatibility........................................................ 40- 238 Failure code [CA351] Injectors Drive Circuit Error............................................................... 40- 239 Failure code [CA352] Sens Supply 1 Volt Low Error ........................................................... 40- 240 Failure code [CA386] Sens Supply 1 Volt High Error .......................................................... 40- 242 Failure code [CA441] Battery Voltage Low Error................................................................. 40- 243 Failure code [CA442] Battery Voltage High Error ................................................................ 40- 244 Failure code [CA449] Rail Press Very High Error................................................................ 40- 245 Failure code [CA451] Rail Press Sensor High Error............................................................ 40- 246 Failure code [CA452] Rail Press Sensor Low Error............................................................. 40- 248 Failure code [CA553] Rail Press High Error ........................................................................ 40- 250 Failure code [CA554] Rail Press Sensor In Range Error..................................................... 40- 251 Failure code [CA559] Rail Press Low Error ......................................................................... 40- 252 Failure code [CA689] Eng Ne Speed Sensor Error ............................................................. 40- 256 Failure code [CA731] Eng Bkup Speed Sens Phase Error.................................................. 40- 258 Failure code [CA757] All Continuous Data Lost Error.......................................................... 40- 259 Failure code [CA778] Eng Bkup Speed Sensor Error.......................................................... 40- 260 Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 40- 262 Failure code [CA2185] Throt Sens Sup Volt High Error....................................................... 40- 263 Failure code [CA2186] Throt Sens Sup Volt Low Error ....................................................... 40- 264 Failure code [CA2249] Rail Press Very Low Error............................................................... 40- 265 00-3-3 (01)
  • 8. Shop Manual Table of contents D375A-6R Failure code [D110KB] Battery Relay: Drive Short Circuit................................................... 40- 266 Failure code [D130KA] Neutral relay: Disconnection........................................................... 40- 268 Failure code [D130KB] Neutral relay: Short circuit .............................................................. 40- 270 Failure code [D161KA] Back-up alarm releay: Disconnection ............................................. 40- 272 Failure code [D161KB] Back-up alarm releay: Short circuit................................................. 40- 274 Failure code [D182KZ] Preheater Relay Abnormality.......................................................... 40- 276 Failure code [D190KA] ACC signal relay: Disconnection .................................................... 40- 278 Failure code [D190KB] ACC signal relay: Short circuit........................................................ 40- 280 Failure code [D1EFKA] Pre lub. motor relay: Disconnection ............................................... 40- 282 Failure code [D1EFKB] Pre lub. motor relay: Short circuit................................................... 40- 284 Failure code [DAFRKR] Monitor: Can communication lost (PT).......................................... 40- 286 Failure code [dAFRKR] Monitor: CAN communication lost (WE) ........................................ 40- 287 Failure code [DAFRMC] CAN Discon (Monitor Detected) ................................................... 40- 288 Failure code [DB2RKR] ENG cont.: Can communication lost (PT) ..................................... 40- 294 Failure code [dB2RKR] ENG controller: CAN communication lost (WE)............................. 40- 298 Failure code [DB90KT] WE controller: Abnormality in controller ......................................... 40- 299 Failure code [DB91KK] WE controller: Source voltage reduction........................................ 40- 300 Failure code [DB92KK] WE controller: Output voltage reduction ........................................ 40- 302 Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction ................................... 40- 304 Failure code [DB99KQ] WE controller: Type select signal .................................................. 40- 306 Failure code [DB9RKR] WE controller: Can communication lost (PT) ................................ 40- 307 Failure code [DBB0KK] VHMS controller:Source voltage reduction.................................... 40- 310 Failure code [DBB0KQ] VHMS connector connection abnormality ..................................... 40- 312 Failure code [DBB3KK] VHMS controller: Source voltage reduction................................... 40- 313 Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction ..................................... 40- 316 Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction ...................................... 40- 318 Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction ...................................... 40- 320 Failure code [DBBQKR] PT cont.: Can communication lost (VHMS) .................................. 40- 322 Failure code [DBE0KT] PT controller: Abnormality in controller .......................................... 40- 323 Failure code [DBE1KK] PT controller: Source voltage reduction......................................... 40- 324 Failure code [DBE2KK] PT controller: Output voltage reduction ......................................... 40- 326 Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction.................................... 40- 328 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction ........................................ 40- 330 Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction ......................................... 40- 332 Failure code [DBE9KQ] PT controller: Type select signal ................................................... 40- 334 Failure code [DBERKR] PT controller: Can communication lost (WE) ................................ 40- 335 Failure code [DD12KA] Shift up Sw: Disconnection ............................................................ 40- 338 Failure code [DD12KB] Shift up Sw: Short circuit................................................................ 40- 340 Failure code [DD13KA] Shift down Sw: Disconnection........................................................ 40- 342 Failure code [DD13KB] Shift down Sw: Short circuit ........................................................... 40- 344 Failure code [DD14KA] Parking lever Sw: Dissconnection.................................................. 40- 346 Failure code [DD14KB] Parking lever Sw: Short circuit ....................................................... 40- 348 Failure code [DDB9L4] Reverse SW Signal disagreement ................................................. 40- 350 Failure code [DDE2KA] Pre lub. oil press sw: Disconnection.............................................. 40- 352 Failure code [DDK3L4] Forward SW Signal disagreement.................................................. 40- 354 Failure code [DDK5KA] Shift switch disconnection ............................................................. 40- 356 Failure code [DDK5KB] Shift switch short circuit ................................................................. 40- 358 Failure code [DDN2LD] Blade tilt RH pressure SW abnormality ......................................... 40- 360 Failure code [DDN3LD] Blade tilt LH pressure SW abnormality.......................................... 40- 362 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection.......................................... 40- 364 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit ............................................. 40- 366 Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection .............................................. 40- 368 Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit.................................................. 40- 370 Failure code [DDNALD] Blade lift up pressure SW abnormality .......................................... 40- 372 (01) 00-3-4
  • 9. Shop Manual Table of contents D375A-6R Failure code [DDNBLD] Ripper lift up pressure SW abnormality......................................... 40- 374 Failure code [DDNCLD] Ripper lift down pressure SW abnormality.................................... 40- 376 Failure code [DDNDLD] Ripper tilt in pressure SW abnormality.......................................... 40- 378 Failure code [DDNELD] Ripper tilt back pressure SW abnormality ..................................... 40- 380 Failure code [DDNFLD] Blade lift down pressure SW abnormality...................................... 40- 382 Failure code [DDNLKA] Weq lock Sw: Disconnection ......................................................... 40- 384 Failure code [DDNLKB] Weq lock Sw: Short circuit............................................................. 40- 386 Failure code [DDT5KA] Neutral switch disconnection ......................................................... 40- 388 Failure code [DDT5KB] Neutral switch short circuit............................................................. 40- 390 Failure code [DDT5KQ] Lever SPEC selection signal disagreement .................................. 40- 392 Failure code [DDTSL1] S/C: Fill high................................................................................... 40- 394 Failure code [DDTSLH] S/C: Fill low.................................................................................... 40- 396 Failure code [DGE5KX] Ambient temp sensor abnormality................................................. 40- 398 Failure code [DGS1KX] Hyd oil temp: signal abnormal ....................................................... 40- 400 Failure code [DGT1KA] T/C oil temp sensor: Abnormal ...................................................... 40- 402 Failure code [DGT1KX] T/C oil temp sensor: Abnormal ...................................................... 40- 404 Failure code [DGT5KA] F exhaust temp sensor disconnection ........................................... 40- 406 Failure code [DGT5KB] F exhaust temp sensor short circuit............................................... 40- 408 Failure code [DGT6KA] R exhaust temp sensor disconnection........................................... 40- 410 Failure code [DGT6KB] R exhaust temp sensor short circuit .............................................. 40- 412 Failure code [DH21KA] Weq pressure sensor: Disconnection ............................................ 40- 414 Failure code [DH21KB] Weq pressure sensor: Short circuit................................................ 40- 416 Failure code [DHE5KB] ENG blow-by pressure sensor disconnection................................ 40- 418 Failure code [DHE5KY] ENG blow-by pressure sensor short circuit ................................... 40- 420 Failure code [DHT3KX] T/M oil pressure sensor abnormality.............................................. 40- 422 Failure code [DHT5KA] T/C in-pressure sensor: Disconnection.......................................... 40- 424 Failure code [DHT5KB] T/C in-pressure sensor: Short circuit ............................................. 40- 426 Failure code [DHT7KA] T/C out-pressure sensor: Disconnection........................................ 40- 428 Failure code [DHT7KB] T/C out-pressure sensor: Short circuit ........................................... 40- 430 Failure code [DK10KA] Fuel control Dial: Disconnection..................................................... 40- 432 Failure code [DK10KB] Fuel control Dial: Short circuit ........................................................ 40- 434 Failure code [DK30KA] ST lever 1: Disconnection .............................................................. 40- 436 Failure code [DK30KB] ST lever 1: Short circuit.................................................................. 40- 438 Failure code [DK30KX] ST lever: Out of normal range........................................................ 40- 440 Failure code [DK30KZ] ST lever: Disconnection or short circuit.......................................... 40- 441 Failure code [DK30L8] ST lever: Signal mismatch .............................................................. 40- 442 Failure code [DK31KA] ST lever 2: Disconnection .............................................................. 40- 444 Failure code [DK31KB] ST lever 2: Short circuit.................................................................. 40- 446 Failure code [DK40KA] Brake potentiometer: Disconnection .............................................. 40- 448 Failure code [DK40KB] Brake potentiometer: Short circuit.................................................. 40- 450 Failure code [DK55KX] FR lever: Out of normal range........................................................ 40- 452 Failure code [DK55KZ] FR lever: Disconnection or short circuit.......................................... 40- 453 Failure code [DK55L8] FR lever: Signal mismatch .............................................................. 40- 454 Failure code [DK56KA] FR lever 1: Disconnection .............................................................. 40- 456 Failure code [DK56KB] FR lever 1: Short circuit.................................................................. 40- 458 Failure code [DK57KA] FR lever 2: Disconnection .............................................................. 40- 460 Failure code [DK57KB] FR lever 2: Short circuit.................................................................. 40- 462 Failure code [DK60KA] Acceleration sensor: Disconnection ............................................... 40- 464 Failure code [DK60KB] Acceleration sensor: Short circuit................................................... 40- 466 Failure code [DKH1KA] Pitch angle sensor: Disconnection................................................. 40- 468 Failure code [DKH1KB] Pitch angle sensor: Short circuit .................................................... 40- 470 Failure code [DLF1KA] T/C out-speed sensor: Disconnection ............................................ 40- 472 Failure code [DLM3KA] Fan rev. sensor: Disconnection ..................................................... 40- 474 Failure code [DLM3MB] Fan control: Decline ...................................................................... 40- 476 00-3-5 (01)
  • 10. Shop Manual Table of contents D375A-6R Failure code [DLT3KA] T/M out-speed sensor: Disconnection............................................ 40- 477 Failure code [DLT3KB] T/M out-speed sensor: Abnormal ................................................... 40- 478 Failure code [DW59KA] Blade dual selector SOL disconnection ........................................ 40- 479 Failure code [DW59KB] Blade dual selector SOL short circuit ............................................ 40- 480 Failure code [DW59KY] Blade dual selector SOL hot short ................................................ 40- 482 Failure code [DW5AKA] Blade pitch selector SOL disconnection ....................................... 40- 484 Failure code [DW5AKB] Blade pitch selector SOL short circuit........................................... 40- 485 Failure code [DW5AKY] Blade pitch selector SOL Short circuit .......................................... 40- 486 Failure code [DW7BKA] Fan rev EPC: Disconnection......................................................... 40- 488 Failure code [DW7BKB] Fan rev EPC: Short circuit ............................................................ 40- 489 Failure code [DWN3KA] Ssp solenoid: Disconnection ........................................................ 40- 490 Failure code [DWN3KB] Ssp solenoid: Short circuit ............................................................ 40- 492 Failure code [DWN3KY] SSP solenoid: Short circuit ........................................................... 40- 494 Failure code [DWN5KA] Fan pump solenoid 1: Disconnection ........................................... 40- 496 Failure code [DWN5KB] Fan pump solenoid 1: Short circuit............................................... 40- 498 Failure code [DWN5KY] Fan pump solenoid 1: Short circuit............................................... 40- 500 Failure code [DWNCKA] Fan pump solenoid 2: Disconnection........................................... 40- 502 Failure code [DWNCKB] Fan pump solenoid 2: Short circuit .............................................. 40- 504 Failure code [DWNCKY] Fan pump solenoid 2: Short circuit .............................................. 40- 506 Failure code [DXH1KA] Lock-up ECMV: Disconnection...................................................... 40- 508 Failure code [DXH1KB] Lock-up ECMV: Short circuit ......................................................... 40- 509 Failure code [DXH1KY] Lock-up ECMV: Short circuit ......................................................... 40- 510 Failure code [DXH4KA] 1st clutch ECMV: Disconnection ................................................... 40- 512 Failure code [DXH4KB] 1st clutch ECMV: Short circuit ....................................................... 40- 514 Failure code [DXH4KY] 1st clutch ECMV: Short circuit ....................................................... 40- 516 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection .................................................. 40- 518 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit...................................................... 40- 520 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit...................................................... 40- 522 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ................................................... 40- 524 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit....................................................... 40- 526 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit....................................................... 40- 528 Failure code [DXH7KA] R clutch ECMV: Disconnection...................................................... 40- 530 Failure code [DXH7KB] R clutch ECMV: Short circuit ......................................................... 40- 532 Failure code [DXH7KY] R clutch ECMV: Short circuit ......................................................... 40- 534 Failure code [DXH8KA] F clutch ECMV: Disconnection ...................................................... 40- 536 Failure code [DXH8KB] F clutch ECMV: Short circuit.......................................................... 40- 538 Failure code [DXH8KY] F clutch ECMV: Short circuit.......................................................... 40- 540 Failure code [DXH9KA] Right clutch ECMV: Disconnection................................................ 40- 542 Failure code [DXH9KB] Right clutch ECMV: Short circuit ................................................... 40- 544 Failure code [DXH9KY] Right clutch ECMV: Short circuit ................................................... 40- 546 Failure code [DXHAKA] Left clutch ECMV: Disconnection.................................................. 40- 548 Failure code [DXHAKB] Left clutch ECMV: Short circuit ..................................................... 40- 550 Failure code [DXHAKY] Left clutch ECMV: Short circuit ..................................................... 40- 552 Failure code [DXHBKA] Right brake ECMV: Disconnection................................................ 40- 554 Failure code [DXHBKB] Right brake ECMV: Short circuit ................................................... 40- 556 Failure code [DXHBKY] Right brake ECMV: Short circuit ................................................... 40- 558 Failure code [DXHCKA] Left brake ECMV: Disconnection.................................................. 40- 560 Failure code [DXHCKB] Left brake ECMV: Short circuit...................................................... 40- 562 Failure code [DXHCKY] Left brake ECMV: Short circuit...................................................... 40- 564 Failure code [DXJBKA] S/C ECMV: Disconnection ............................................................. 40- 566 Failure code [DXJBKB] S/C ECMV: Short circuit................................................................. 40- 567 Failure code [DXJBKY] S/C ECMV: Short circuit................................................................. 40- 568 Failure code [DY2HKA] Pre lub. motor: Disconnection ....................................................... 40- 570 Failure code [F@BBZL] ENG blow-by pressure high level.................................................. 40- 572 (01) 00-3-6
  • 11. Shop Manual Table of contents D375A-6R Failure code [F@BYNR] F exhaust temp high level (2)....................................................... 40- 573 Failure code [F@BYNS] F exhaust temp high level (1) ....................................................... 40- 574 Failure code [F@BZNR] R exhaust temp high level (2)....................................................... 40- 575 Failure code [F@BZNS] R exhaust temp high level (1)....................................................... 40- 576 Troubleshooting of electrical system (E-mode)....................................................................... 40- 578 Information contained in troubleshooting table .................................................................... 40- 578 E-1 Engine does not start (starting motor does not turn)..................................................... 40- 580 E-2 Preheater does not operate........................................................................................... 40- 584 E-3 When starting switch is turned ON, machine monitor displays nothing......................... 40- 588 E-4 When starting switch is turned ON (before starting engine), basic check item lights up 40- 592 E-5 Precaution item lights up while engine is running ......................................................... 40- 594 E-6 Emergency stop item lights up while engine is running................................................. 40- 596 E-7 Engine coolant temperature gauge does not indicate normally .................................... 40- 597 E-8 Fuel gauge does not indicate properly .......................................................................... 40- 598 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ............... 40- 600 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally..................... 40- 601 E-11 Contents of display by machine monitor are different from applicable machine ......... 40- 602 E-12 Machine monitor does not display some items ........................................................... 40- 602 E-13 Function switch does not work .................................................................................... 40- 602 E-14 Operation mode does not change............................................................................... 40- 603 E-15 Gearshift mode does not change ................................................................................ 40- 603 E-16 Customize function does not operate normally ........................................................... 40- 604 E-17 Customize memory function does not operate normally ............................................. 40- 604 E-18 Alarm buzzer does not sound or does not stop........................................................... 40- 605 E-19 When starting switch is turned OFF, service meter is not displayed........................... 40- 605 E-20 Machine monitor cannot be set in service mode......................................................... 40- 605 E-21 The ripper pin puller cylinder does not operate........................................................... 40- 606 E-22 Horn does not sound or does not stop ........................................................................ 40- 608 E-23 Back-up alarm does not sound or does not stop......................................................... 40- 610 E-24 Fan does not reverse .................................................................................................. 40- 612 E-25 The head lamp and rear lamp do not light up.............................................................. 40- 613 E-26 Windshield wiper does not operate ............................................................................. 40- 622 E-27 Window washer does not operate............................................................................... 40- 630 E-28 Electric priming pump does not operate or does not stop automatically..................... 40- 638 E-29 Orbcomm terminal does not operate normally (Data are not transmitted) .................. 40- 640 E-30 Gear cannot be shifted................................................................................................ 40- 642 Troubleshooting of hydraulic and mechanical system (H-mode) ............................................ 40- 644 Information in troubleshooting table..................................................................................... 40- 644 List of Failure Modes and Causes ....................................................................................... 40- 646 H-1 Machine lacks power(or drawbar pull) .......................................................................... 40- 648 H-2 Machine cannot travel (at 2nd or 3rd each speed)........................................................ 40- 650 H-3 Machine cannot travel at any gear speeds ................................................................... 40- 651 H-4 Machine travels only in one direction, forward or reverse............................................. 40- 653 H-5 Large time lag at gear shifting or directional change .................................................... 40- 654 H-6 Machine connot turn...................................................................................................... 40- 655 H-7 Machine turns only to one side ..................................................................................... 40- 656 H-8 Machine overruns at turnning........................................................................................ 40- 657 H-9 Brake does not work ..................................................................................................... 40- 658 H-10 Torque converter does not lock up.............................................................................. 40- 659 H-11 Power train oil overheats............................................................................................. 40- 660 H-12 All work equipment operates too slow or lacks power ................................................ 40- 661 H-13 All work equipment does not operate.......................................................................... 40- 662 H-14 Blade lift cylinder speed is too slow or lacks power .................................................... 40- 663 H-15 Blade tilt cylinder speed is too slow or lacks power .................................................... 40- 664 00-3-7 (01)
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  • 13. Shop Manual Table of contents D375A-6R H-16 Ripper lift cylinder speed is too slow or lacks power................................................... 40- 665 H-17 Ripper tilt cylinder speed is too slow or lacks power................................................... 40- 666 H-18 Excessive hydraulic drift of blade lift cylinder.............................................................. 40- 667 H-19 Excessive hydraulic drift of blade tilt cylinder.............................................................. 40- 668 H-20 Excessive hydraulic drift of ripper lift cylinder ............................................................. 40- 669 H-21 Ripper pin puller cylinder does not operate (machine with giant ripper) ..................... 40- 670 H-22 Blade pitch does not work (machine with dual tilt specification) ................................. 40- 671 H-23 Abnormal noise from around work equipment pump .................................................. 40- 672 H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)40-673 Troubleshooting of engine (S-mode) ...................................................................................... 40- 674 Method of using troubleshooting chart................................................................................. 40- 674 S-1 Engine does not start easily.......................................................................................... 40- 678 S-2 Engine does not start .................................................................................................... 40- 679 S-3 Engine does not rev up smoothly (response-up is poor)............................................... 40- 682 S-4 Engine stops during operation ...................................................................................... 40- 683 S-5 Engine does not rotate smoothly (hunting) ................................................................... 40- 684 S-6 Engine lacks power (or output shortage) ...................................................................... 40- 685 S-7 Exhaust smoke is black (Incomplete combustion) ........................................................ 40- 686 S-8 Oil is consumption is excessive(or exhaust smoke is blue) .......................................... 40- 687 S-9 Engine oil becomes contaminated quickly .................................................................... 40- 688 S-10 Fuel consumption is excessive ................................................................................... 40- 689 S-11 Oil mixes into coolant(coolant blows back or is reduced) ........................................... 40- 690 S-12 Engine pressure monitor lights up (drop in engine oil pressure)................................. 40- 691 S-13 Oil level rises (Coolant or fuel mixes into oil) .............................................................. 40- 692 S-14 Coolant temperature rises too high (overheating)....................................................... 40- 693 S-15 Abnormal noise is heard ............................................................................................. 40- 694 S-16 Vibration is excessive.................................................................................................. 40- 695 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)............................ 40- 696 50 Disassembly and assembly General information on disassembly and assembly ............................................................... 50- 4 How to read this manual...................................................................................................... 50- 4 Coating materials list ........................................................................................................... 50- 6 Special tool list..................................................................................................................... 50- 9 Sketches of special tools ..................................................................................................... 50- 17 Engine and cooling system..................................................................................................... 50- 25 Removal and installation of fuel supply pump assembly ..................................................... 50- 25 Removal and installation of fuel injector assembly .............................................................. 50- 30 Removal and installation of cylinder head assembly ........................................................... 50- 35 Removal and installation of radiator guard assembly .......................................................... 50- 50 Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)50- 55 Removal and installation of radiator .................................................................................... 50- 60 Removal and installation of hydraulic oil cooler................................................................... 50- 62 Removal and installation of aftercooler................................................................................ 50- 63 Removal and installation of engine assembly...................................................................... 50- 64 Removal and installation of engine hood assembly............................................................. 50- 71 Removal and installation of engine front seal...................................................................... 50- 74 Removal and installation of engine rear seal....................................................................... 50- 76 Removal and installation of fan drive assembly................................................................... 50- 80 Removal and installation of fan motor assembly ................................................................. 50- 82 Removal and installation of fuel tank assembly................................................................... 50- 84 Power train.............................................................................................................................. 50- 86 Removal and installation of damper assembly .................................................................... 50- 86 (01) 00-3-8
  • 14. Shop Manual Table of contents D375A-6R Disassembly and assembly of damper assembly................................................................ 50- 90 Removal and installation of power train unit assembly........................................................ 50- 93 Disconnection and connection of power train unit assembly ............................................... 50- 99 Disassembly and assembly of PTO assembly..................................................................... 50- 108 Disassembly and assembly of torque converter assembly.................................................. 50- 114 Disassembly and assembly of TORQFLOW transmission assembly .................................. 50- 123 Disassembly and assembly of steering case assembly....................................................... 50- 150 Removal and installation of power train pump and lubrication pump assembly .................. 50- 166 Removal and installation of scavenging pump assembly .................................................... 50- 167 Removal and installation of final drive assembly ................................................................. 50- 168 Disassembly and assembly of final drive assembly............................................................. 50- 170 Undercarriage and frame ........................................................................................................ 50- 183 Removal and installation of track frame assembly............................................................... 50- 183 Removal and installation of idler assembly.......................................................................... 50- 188 Disassembly and assembly of idler assembly ..................................................................... 50- 189 Removal and installation of recoil spring assembly ............................................................. 50- 193 Disassembly and assembly of recoil spring assembly......................................................... 50- 198 Removal and installation of track roller assembly................................................................ 50- 200 Disassembly and assembly of track roller assembly ........................................................... 50- 203 Removal and installation of carrier roller assembly ............................................................. 50- 206 Disassembly and assembly of carrier roller assembly......................................................... 50- 207 Removal and installation of bogie assembly........................................................................ 50- 211 Disassembly and assembly of bogie assembly ................................................................... 50- 216 Removal and installation of first bogie assembly................................................................. 50- 218 Separation and connection of track shoe assembly ............................................................ 50- 223 Overall disassembly and assembly of track shoe................................................................ 50- 227 Link press press-fitting jig dimensions ................................................................................. 50- 244 Disassembly and assembly of one link assembly in the field .............................................. 50- 245 Disassembly and assembly of master link........................................................................... 50- 250 Removal and installation of pivot shaft assembly ................................................................ 50- 254 Removal and installation of equalizer bar............................................................................ 50- 255 Disassembly and assembly of equalizer bar bushing.......................................................... 50- 259 Removal and installation of segment tooth.......................................................................... 50- 261 Hydraulic system..................................................................................................................... 50- 262 Removal and installation of hydraulic tank assembly .......................................................... 50- 262 Removal and installation of work equipment pump assembly ............................................. 50- 265 Removal and installation of fan pump assembly.................................................................. 50- 269 Removal and installation of control valve assembly ............................................................ 50- 271 Disassembly and assembly of control valve assembly........................................................ 50- 273 Disassembly and assembly of blade PPC valve assembly.................................................. 50- 278 Disassembly and assembly of ripper PPC valve assembly ................................................. 50- 281 Disassembly and assembly of hydraulic cylinder assembly ................................................ 50- 283 Disassembly and assembly of ripper pin puller cylinder assembly...................................... 50- 291 Work equipment...................................................................................................................... 50- 294 Removal and installation of blade assembly........................................................................ 50- 294 Disassembly and assembly of blade assembly ................................................................... 50- 296 Disassembly and assembly of giant ripper assembly .......................................................... 50- 300 Cab and its attachments ......................................................................................................... 50- 303 Removal and installation of ROPS guard ............................................................................ 50- 303 Removal and installation of operator's cab assembly.......................................................... 50- 304 Removal and installation of floor frame assembly ............................................................... 50- 308 Removal and installation of air conditioner unit assembly ................................................... 50- 313 00-3-9 (01)
  • 15. Shop Manual Table of contents D375A-6R Electrical system..................................................................................................................... 50- 319 Removal and installation of transmission controller assembly and steering controller assembly ............................................................................................................................................. 50- 319 Removal and installation of engine controller assembly...................................................... 50- 320 Removal and installation of VHMS controller assembly ...................................................... 50- 322 Removal and installation of machine monitor assembly...................................................... 50- 323 60 Maintenance Standard Engine and cooling system..................................................................................................... 60- 3 Engine mount....................................................................................................................... 60- 3 Cooling fan pump................................................................................................................. 60- 5 Cooling fan motor ................................................................................................................ 60- 12 Power train.............................................................................................................................. 60- 14 Power train unit.................................................................................................................... 60- 14 Damper and universal joint.................................................................................................. 60- 16 Torque converter and PTO.................................................................................................. 60- 19 Main relief valve and torque converter relief valve .............................................................. 60- 22 Lockup clutch ECMV and stator clutch ECMV..................................................................... 60- 23 Scavenging pump................................................................................................................ 60- 24 Transmission control............................................................................................................ 60- 25 Transmission ....................................................................................................................... 60- 26 Transmission lubricating oil relief valve ............................................................................... 60- 31 Power train and lubrication pump ........................................................................................ 60- 32 Transfer, bevel gear shaft and steering unit ........................................................................ 60- 34 Steering control valve .......................................................................................................... 60- 40 Steering clutch ECMV and steering brake ECMV ............................................................... 60- 41 Parking brake valve ............................................................................................................. 60- 42 Final drive ............................................................................................................................ 60- 43 Sprocket............................................................................................................................... 60- 46 Undercarriage and frame........................................................................................................ 60- 48 Track frame.......................................................................................................................... 60- 48 Idler cushion cushion........................................................................................................... 60- 50 Idler...................................................................................................................................... 60- 52 Track roller........................................................................................................................... 60- 54 Carrier roller......................................................................................................................... 60- 56 Track roller bogie................................................................................................................. 60- 57 Track shoe........................................................................................................................... 60- 58 Main frame........................................................................................................................... 60- 62 Suspension.......................................................................................................................... 60- 64 Hydraulic system .................................................................................................................... 60- 68 PPC valve............................................................................................................................ 60- 68 Hydraulic cylinder ................................................................................................................ 60- 74 Quick drop valve.................................................................................................................. 60- 77 Work equipment pump......................................................................................................... 60- 78 Control valve........................................................................................................................ 60- 81 Self-pressure reducing valve ............................................................................................... 60- 94 Work equipment...................................................................................................................... 60- 97 Cylinder stay ........................................................................................................................ 60- 97 Blade.................................................................................................................................... 60- 98 Cutting edge and end bit...................................................................................................... 60- 102 Ripper .................................................................................................................................. 60- 104 80 Appendix Air conditioner......................................................................................................................... 80- 3 (01) 00-3-10
  • 16. Shop Manual Table of contents D375A-6R Precautions for refrigerant ................................................................................................... 80- 3 Air conditioner component ................................................................................................... 80- 4 Configuration and function of refrigeration cycle.................................................................. 80- 6 Outline of refrigeration cycle ................................................................................................ 80- 7 Air conditioner unit ............................................................................................................... 80- 10 Blower unit ........................................................................................................................... 80- 14 FRESH/RECIRC air changeover damper............................................................................ 80- 15 Compressor ......................................................................................................................... 80- 16 Condenser ........................................................................................................................... 80- 17 Receiver drier....................................................................................................................... 80- 18 Air conditioner control panel ................................................................................................ 80- 20 Procedure for testing and troubleshooting........................................................................... 80- 22 Circuit diagram and arrangement of connector pins............................................................ 80- 24 System diagram................................................................................................................... 80- 26 Parts and connectors layout ................................................................................................ 80- 28 Testing temperature control................................................................................................. 80- 32 Testing FRESH/RECIC air changeover............................................................................... 80- 33 Testing relay ........................................................................................................................ 80- 34 Troubleshooting chart 1 ....................................................................................................... 80- 36 Troubleshooting chart 2 ....................................................................................................... 80- 38 Information in troubleshooting table..................................................................................... 80- 40 Troubleshooting for power supply system (Air conditioner does not operate)..................... 80- 42 Troubleshooting for compressor system (Air is not cooled)................................................. 80- 44 Troubleshooting for blower motor system (Air does not come out or air flow is abnormal) . 80- 48 Troubleshooting for temperature control.............................................................................. 80- 54 Troubleshooting for FRESH/RECIRC air changeover ......................................................... 80- 56 Troubleshooting with gauge pressure.................................................................................. 80- 58 Connection of service tool.................................................................................................... 80- 60 Precautions for disconnecting and connecting .................................................................... 80- 62 Handling of compressor oil .................................................................................................. 80- 64 90 Diagrams and Drawings Hydraulic diagrams and drawings........................................................................................... 90- 3 Symbols used in hydraulic circuit diagrams......................................................................... 90- 3 Power train hydraulic diagrams and drawings ..................................................................... 90- 5 Hydraulic circuit diagram...................................................................................................... 90- 7 Electrical diagrams and drawings ........................................................................................... 90- 11 Symbols used in electrical circuit diagrams ......................................................................... 90- 11 Electrical circuit diagram...................................................................................................... 90- 15 Index ....................................................................................................................................... 1 00-4 (01)
  • 17. D375A-6R Forword and general information 00-5 Safety notice 00-5 Important safety notice Appropriate servicing and repair are extremely important to ensure safe operation of the machine.The shop manuals describe the effective and safe servicing and repair methods recommended by Komat- su.Some of the servicing and repair methods require use of special tools designed by Komatsu for special purposes. The symbol mark "k" is indicated for matters that require special precautions for such work.The work indicated with the warning mark should be carried out along to the instructions with special at- tention to the precautions.Should a hazardous situation occur or be anticipated during such work, be sure to proceed it safe and take every necessary measure. 1. General precautions k Inappropriate handling creates an ex- treme danger.Read and understand what is described in the Operation and Mainte- nance Manual before operating the ma- chine.Read and understand what is described in this manual before starting work. 1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precau- tions, see the Operation and Maintenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear the safety glasses when hit- ting parts with a hammer q Always wear safety glasses when grind- ing parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning tag in the oper- ator's compartment. 5) Only qualified workers must carry out work and operation which require license or quali- fication. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thor- oughly check the tools, machine, forklift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condi- tion. 9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. (Rev. 2010/02) Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signals Prohibition of operation and handling by unli- censed workers 6 Safety check before starting work Wearing protective goggles(for cleaning or grind- ing work) Wearing shielding goggles and protectors(for welding work) 9 Good physical condition and preparation Precautions against work which you are not used to or you are used to too much 00-5 Forword and general information Safety notice 10 5 7 8