Komatsu D375A-5 Bulldozer (18001 and up) Shop Manual - SEBM023508

This complete service repair workshop manual PDF download for the Komatsu D375A-5 Bulldozer (SN: 18001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D375A-5
Serial Numbers : 18001 and up
Engine : SA6D170E-3


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- MAINTENANCE STANDARD
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM023508
Total Pages : 985


D375A-5 mounts the SA6D170E-3 engine.
For details of the engine, see the 170-3 Series Engine Shop Manual.

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

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

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TABLE OF CONTENTS :

01 GENERAL
SPECIFICATION DRAWING
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL,COOLANT AND LUBRICANT

10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD
POWER TRAIN
OVERALL DRAWING OF POWER TRAIN UNIT
POWER TRAIN HYDRAULIC PIPING DRAWING
DAMPER,UNIVERSAL JOINT
TORQUE CONVERTER,PTO
TORQUE CONVERTER VALVE
SCAVENGING PUMP
TRANSMISSION CONTROL
TRANSMISSION
TRANSMISSION ECMV
TRANSMISSION LUBRICATION RELIEF VALVE
POWER TRAIN PUMP+LUBRICATION PUMP
STEERING,BRAKE CONTROL
TRANSFER,BEVEL GEAR SHAFT,STEERING
STEERING ECMV
STEERING CLUTCH,STEERING BRAKE ECMV
PARKING BRAKE VALVE
SUDDEN STOPS PREVENTION VALVE
FINAL DRIVE
TRACK FRAME
RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK ROLLER BOGIE
TRACK SHOE
MAIN FRAME
SUSPENSION
WORK EQUIPMENT HUDRAULIC PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM
WORK EQUIPMENT CONTROL
HYDRAULIC TANK
PPC CHARGE VALVE
ACCUMULATOR
PPC LOCK VALVE
PPC VALVE
WORK EQUIPMENT CYLINDER
PISTON VALVE
QUICK DROP VALVE
PIN PULLER SWITCH
PIN PULLER SOLENOID VALVE
BLADE CONTROL KNOB
PITCH, DUAL TILT SOLENOID VALVE
WORK EQUIPMENT+PPC CHARGE PUMP
MAIN CONTROL VALVE
CYLINDER STAY
BLADE
RIPPER EQUIPMENT
CAB MOUNT
CAB
AIR CONDITIONER
ENGINE CONTROL
ENGINE CONTROL SYSTEM
DECELERATOR POTENTIOMETER
HPI ENGINE CONTROL SYSTEM
MONITOR SYSTEM
MONITOR PANEL
SENSORS
MODE SELECTION SYSTEM
SENSORS
ELECTRICAL DEVICE
STEERING ELECTRONIC CONTROL

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR MACHINE RELATED PARTS
TESTING AND ADJUSTING
TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
MEASURING ENGINE SPEED
MEASURING INTAKE AIR PRESSURE(BOOST PRESSURE)
MEASURING EXHAUST TEMPERATURE
MEASURING EXHAUST COLOR
TROUBLESHOOTING FOR INJECTOR
ADJUSTING VALVE CLEARANCE
ADJUSTING INJECTOR SET LOAD
MEASURING COMPRESSION PRESSURE
MEASURING BLOW-BY PRESSURE
MEASURING ENGINE OIL PRESSURE
HANDLING EQUIPMENT IN FUEL SYSTEM
MEASURING FUEL CIRCUIT PRESSURE
VISUAL INSPECTION OF RETURN FUEL
ARRANGEMENT OF CONTROL DEVICES FOR HPI
BLEEDING AIR FROM FUEL CIRCUIT
ADJUSTING ENGINE SPEED SENSOR
REPLACING AND ADJUSTING FAN BELT
TESTING AND ADJUSTING ALTERNATOR, AIR CONDITIONER COMPRESSOR BELT TENSION
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL
MEASURING POWER TRAIN OIL PRESSURE
ADJUSTING TRANSMISSION SPEED SENSOR
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER
ADJUSTING POSITION OF PCCS LEVER CONSOLE
EMERGENCY ESCAPE METHOD WHEN THERE IS FAILURE IN POWER TRAIN
ADJUSTING IDLER CLEARANCE
CHECKING WEAR OF SPROCKET
TESTING AND ADJUSTING TRACK SHOE TENSION
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE
MEASURING PPC VALVE OUTPUT PRESSURE
ADJUSTING PLAY OF PPC VALVE
MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER
MEASURING LEAKAGE INSIDE WORK EQUIPMENT CYLINDER
RELEASING REMAINING PRESSURE IN WORK EQUIPMENT CYLINDERS
BLEEDING AIR FROM WORK EQUIPMENT CYLINDERS
ADJUSTING RIPPER LEVER POSITION
ADJUSTING SAFETY LOCK LEVER
ADJUSTING BLADE
ADJUSTMENT OF PCCS LEVER POTENTIOMETERS
CHECKING THE ADJUSTMENT OF PCCS LEVER
DISASSEMBLY AND ASSEMBLY OF PCCS LEVER
SPECIAL FUNCTIONS OF MONITOR PANEL(EMMS)
PREPARATORY WORK WHEN TROUBLESHOOTING ELECTRICAL SYSTEM
PM CLINIC SERVICE
UNDERCARRIAGE TROUBLESHOOTING REPORT(NORMAL)
UNDERCARRIAGE TROUBLESHOOTING REPORT(IMPACT)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
CLASSIFICATION OF AND PROCEDURE FOR TROUBLESHOOTING
CONNECTOR ALLOCATION DRAWING DRAWING AND ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
T-BRANCH BOX AND T-BRANCH TABLE
TROUBLESHOOTING WHEN SERVICE CODE IS DISPLAYED(SERVICE CODE)
INFORMATION IN TROUBLESHOOTING TABLE
SERVICE CODE[E0101][ABNORMALITY IN NETWORK SYSTEM(STEERING)]
SERVICE CODE[E0104][ABNORMALITY IN NETWORK SYSTEM(MONITOR PANEL)]
SERVICE CODE[E0105][ABNORMALITY IN NETWORK SYSTEM(STEERING)]
SERVICE CODE[E0111](ABNORMALITY IN STEERING CONTROLLER POWER SUPPLY SYSTEM)
SERVICE CODE[E0112](ABNORMALITY IN TRANSMISSION CONTROOLER POWER SUPPLY SYSTEM)
SERVICE CODE[E0120](SHORT CIRCUIT IN CAUTION LAMP SYSTEM)
SERVICE CODE[E0121](SHORT CIRCUIT IN CAUTION BUZZER SYSTEM)
SERVICE CODE[E0142](ABNORMALITY IN TRANSMISSION CONTROLLER 5 V POWER SUPPLY SYSTEM)
SERVICE CODE[E0143](ABNORMALITY IN STEERING CONTROLLER 5 V POWER SUPPLYS SYSTEM)
SERVICE CODE[E0145](ABNORMALITY IN STEERING CONROLLER 24 V POWER SUPPLY SYSTEM)
SERVICE CODE[E0146](ABNORMALITY IN TRANSMISSION ON CONTROLLER 24 V POWER SUPPLY SYSTEM)
SERVICE CODE[E0151](ABNORMALITY IN SELECTION OF STEERING CONTROLLER SPECIFICATION)
SERVICE CODE[E0152][ABNORMALITY IN NETWORK SYSTEM(STEERING)]
SERVICE CODE[E0160](ABNORMALITY IN TRANSMISSION CONTROLLER ROM)
SERVICE CODE[E0161](ABNORMALITY IN STEERING CONTROLLER ROM)
SERVICE CODE[E0164][ABNORMALITY IN NETWORK SYSTEM(TRANSMISSION)]
SERVICE CODE[E0176](DISCONNECTION IN BATTERY REPLAY SYSTEM)
SERVICE CODE[E0177](SHORT CIRCUIT IN BATTERY RELAY SYSTEM)
SERVICE CODE[E0178](DISCONNECTION IN NEUTRAL SAFETY RELAY SYSTEM)
SERVICE CODE[E0179](SHORT CIRCUIT IN NEUTRAL SAFETY RELAY SYSTEM)
SERVICE CODE[E0211](ABNORMAL TORQUE CONVERTER OIL TEMPERATURE)
SERVICE CODE[E0212](SHORT CIRCUIT IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)
SERVICE CODE[E0213](DISCONNECTION IN TORQUE CONVERTER LOCK-UP SOLENOID SYSTEM)
SERVICE CODE[E0221](DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)
SERVICE CODE[E0225](SLIP OF POWER TRAIN CLUTCH)
SERVICE CODE[E0230][ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS(1)]
SERVICE CODE[E0231][ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS(2)]
SERVICE CODE[E0232] [ABNORMALITY IN BOTH FORWARD-REVERSE POTENTIOMETER SYSTEMS(3)]
SERVICE CODE[E0233](DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 1 SYSTEM)
SERVICE CODE[E0234](DISCONNECTION OR SHORT CIRCUIT IN FORWARD-REVERSE POTENTIOMETER 2 SYSTEM)
SERVICE CODE[E0235](DEVIATION OF FORQARD-REVERSE POTENTIOMETER SYSTEM SIGNALS)
SERVICE CODE[E0236](DISCONNECTION OR SHORT CIRCUIT IN SHIFT-UP SWITCH SYSTEMS)
SERVICE CODE[E0237](DISCONNECTION OR SHORT CIRCUIT IN SHIFT-DOWN SWITCH SYSTEMS)
SERVICE CODE[E0238](DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE LEVER SWITH SYSTEMS)
SERVICE CODE[E0239](DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)
SERVICE CODE[E0250](DISCONNECTION IN TRANSMISSION FORWARD CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0251](SHORT CIRCUIT IN TRANSMISSION FORWARD CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0252](DISCONNECTION IN TRANSMISSION REVERSE CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0253](SHORT CIRCUIT IN TRANSMISSION REVERSE CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0254](DISCONNECTION IN TRAINSMISSION 1ST CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0255](SHORT CIRCUIT IN TRANSMISSION 1ST CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0256](DISCONNECTION IN TRANSMISSION 2ND CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0257](SHORT CIRCUIT IN TRANSMISSION 2ND CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0258](DISCONNECTION IN TRANSMISSION 3RD CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0259](SHORT CIRCUIT IN TRANSMISSION 3RD CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0260](DEFECTIVE ENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)
SERVICE CODE[E0261](DEFECTIVE DISENGAGEMENT OF TRANSMISSION FORWARD CLUTCH)
SERVICE CODE[E0262](DEFECTIVE ENGAGEMENT OF TRANSMISSION REVERSE CLUTH)
SERVICE CODE[E0263](DEFECTIVE DISENGAGEMENT OF TRANSMISSION REVERSE CLUTCH)
SERVICE CODE[E0264](DEFECTIVE ENGAGEMENT OF TRANSMISSION 1ST CLUTCH)
SERVICE CODE[E0265](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 1ST CLUTCH)
SERVICE CODE[E0266](DEFECTIVE ENGAGEMENT OF TRANSMISSION 2ND CLUTCH)
SERVICE CODE[E0267](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 2ND CLUTCH)
SERVICE CODE[E0268](DEFECTIVE ENGAGEMENT OF TRANSMISSION 3RD CLUTCH)
SERVICE CODE[E0269](DEFECTIVE DISENGAGEMENT OF TRANSMISSION 3RD CLUTCH)
SERVICE CODE[E0270][DOUBLE TROUBLE IN TRANSMISSION CLUTCH(DEFECTIVE ENGAGEMENT)]
SERVICE CODE[E0271][DOUBLE TROUBLE IN TRANSMISSION CLUTCH(DEFECTIVE DISENGAGEMENT)]
SERVICE CODE[E0306](SHORT CIRCUIT IN BLADE TILT RIGHT OIL PRESSURE SWITCH SYSTEM)
SERVICE CODE[E0307](SHORT CIRCUIT IN BLADE TILT LEFT OIL PRESSURE SWITCH SYSTEM)
SERVICE CODE[E0308](SHORT CIRCUIT IN RIPPER LIFT RAISE OIL PRESSURE SWITCH SYSTEM)
SERVICE CODE[E0309](SHORT CIRCUIT IN RIPPER LIFT LOWER OIL PRESSURE SWITCH SYSTEM)
SERVICE CODE[E0310](SHORT CIRCUIT IN RIPPER TILT-IN OIL PRESSURE SWITCH SYSTEM)
SERVICE CODE[E0311](DISCONNECTION OR SHORT CIRCUIT IN BLADE PITCH SWITCH SYSTEMS)
SERVICE CODE[E0312](DISCONNECTION OR SHORT CIRCUIT IN BLADE TILT SWITCH SYSTEMS)
SERVICE CODE[E0321](DISCONNECTION IN BLADE DUAL SELECTOR SOLENOID SYSTEM)
SERVICE SODE[E0322](SHORT CIRCUIT IN BLADE DUAL SELECTOR SOLENOID SYSTEM)
SERVICE CODE[E0323](DISCONNECTION IN BLADE PITCH SELECTOR SOLENOID SYSTEM)
SERVICE SODE[E0324](SHORT CIRCUIT IN BLADE PITCH SELECTOR SOLENOID SYSTEM)
SERVICE CODE[E0329](ABNORMAL HYDRAULIC OI TEMPERATURE)
SERVICE CODE[E0364](DISCONNECTION IN FRONT LARGE PUMP OIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[E0365](SHORT CIRCUIT IN FRONT LARGE PUMP OIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[E0366](DISCONNECTION IN CENTER SMALL PUMP OIL PRESSURE SENSOR SUSTEM)
SERVICE CODE[E0367](SHORT CIRCUIT IN CENTER SMALL PUMP OIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[E0405](DISCONNECTION OR SHORT CIRCUIT IN FUEL CONTROL DIAL SYSTEM)
SERVICE CODE[E0430](ENGINE OIL:ABNORMAL OIL PRESSURE)
SERVICE CODE[E0431](ABNORMAL RADIATOR COOLANT LEVEL)
SERVICE CODE[E0432](RADIATOR COLLANT:OVERHEATING)
SERVICE CODE[E0486](ABNORMALITY IN SELECTION OF TRANSMISSION CONTROLLER SPECIFICATION)
SERVICE CODE[E0510](DISCONNECTION OR SHORT CIRCUIT IN ACCELERATION SENSOR SYSTEM)
SERVICE CODE[E0610](DISCONNECTION IN BACK-UP ALARM RELAY SYSTEM)
SERVICE CODE[E0611](SHORT CIRCUIT IN BACK-UP ALARM RELAY SYSTEM)
SERVICE CODE[E0660](DISCONNECTION IN ACC SIGHAL DRIVE RELAY SYSTEM)
SERVICE CODE[E0661](SHORT CIRCUIT IN ACC SIGNAL DRIVE RELAY SYSTEM)
SERVICE CODE[E0721](DISCONNECTION OR SHORT CIRCUIT IN PITCH ANGLE SENSOR SYSTEM)
SERVICE CODE[E0730][ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(1)]
SERVICE CODE[E0731][ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(2)]
SERVICE CODE[E0732][ABNORMALITY IN BOTH STEERING POTENTIOMETER SYSTEMS(3)]
SERVICE CODE[E0733](DISCONNECTION OR SHORT CIRCUIT IN STEERING POTENTIOMETER 1 SYSTEM)
SERVICE CODE[E0734](DISCONNECTION OR SHORT CIRCUIT IN STEERING POTENTIOMETER 2 SYSTEM)
SERVICE CODE[E0735](DEVIATION OF STEERING POTENTIOMETER SYSTEM SIGNALS)
SERVICE CODE[E0736](DISCONNECTION OR SHORT CIRCUIT IN BRAKE POTENTIOMETER SYSTEM)
SERVICE CODE[E0750](DISCONNECTION IN RIGHT STEERING CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0751](SHORT CIRCUIT IN RIGHT STEERING CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0752](DISCONNECTION IN LEFT STEERING CLUTCH EXMV(E-POCV)SYSTEM)
SERVICE CODE[E0753](SHORT CIRCUIT IN LEFT STEERING CLUTCH ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0754](DISCONNECTION IN RIGHT STEERING BRAKE ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0755](SHORT CIRCUIT IN RIGHT STEERING BRAKE ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0756](DISCONNECTION IN LEFT STEERING BRAKE ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0757](SHORT CIRCUIT IN LEFT STEERING BRAKE ECMV(E-POCV)SYSTEM)
SERVICE CODE[E0760](DEFECTIVE ENGAGEMENT OF RIGHT STEERING CLUTCH)
SERVICE CODE[E0761](DEFECTIVE DISENGAGEMENT OF RIGHT STEERING CLUTCH)
SERVICE CODE[E0762](DEFECTIVE ENGAGEMENT OF LEFT STEERING CLUTCH)
SERVICE CODE[E0763](DEFECTIVE DISENGAGEMENT OF LEFT STEERING CLUTCH)
SERVICE CODE[E0764](DEFECTIVE ENGAGEMENT OF RIGHT STEERING BRAKE)
SERVICE CODE[E0765](DEFECTIVE DISENGAGEMENT OF RIGHT STEERING BRAKE)
SERVICE CODE[E0766](DEFECTIVE ENGAGEMENT OF LEFT STEERING BRAKE)
SERVICE CODE[E0767](DEFECTIVE DISENGAGEMENT OF LEFT STEERING BRAKE)
SERVICE CODE[E0779](DISCONNECTION IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)
SERVICE CODE[E0780](SHORT CIRCUIT IN SUDDEN STOP PREVENTION SOLENOID SYSTEM)
SERVICE CODE[E0781](DISCONNECTION OR SHORT CIRCUIT IN PARKING BRAKE LAVER SWITCH SYSTEMS)
SERVICE CODE[E0782](DISAGREEMENT OF PARKING BRAKE LEVER SWITCH SYSTEM SIGNALS)
SERVICE CODE[E0930](DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
SERVICE CODE[E0931](DISCONNECTION IN ENGINE SPEED SENSOR SYSTEM)
SERVICE CODE[E0932](DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)
SERVICE CODE[E0933](DISCONNECTION IN TRANSMISSION SPEED SENSOR SYSTEM)
SERVICE CODE[E1939](ABNORMALITY IN J1939 COMMUNICATION SYSTEM)
SERVICE CODE[EC111](ABNORMALITY IN ENGINE CONTROLLER MEMORY)
SERVICE CODE[EC112](ABNORMALITY IN TIMING RAIL ACTUATOR)
SERVICE CODE[EC113](ABNORMAL CURRENT IN TIMING RAIL ACTUATOR SYSTEM)
SERVICE CODE[EC115](ABNORMALITY IN ENGINE SPEED SENSOR 2 SYSTEMS)
SERVICE CODE[EC116](ABNORMALITY HIGH LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC117](ABNORMALLY LOW LEVEL IN TIMING RAIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC118](ABNORMALITY HIGH LEVEL IN PUEL PUMP PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC119](ABNORMALLY LOW LEVEL IN FUEL PUMP PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC121](ABNORMALITY IN ENGINE SPEED SENSOR 1 SYSTEMS)
SERVICE CODE[EC122](ABNORMALLY HIGH LEVEL IN BOOST PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC123](ABNORMALLY LOW LEVEL IN BOOST PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC131](ABNORMALLY HIGH LEVEL IN THROTTLE SENSOR SYSTEM)
SERVICE CODE[EC132](ABNORMALLY LOW LEVEL IN THROTTLE SENSOR SYSTEM)
SERVICE CODE[EC133](ABNORMALLY HIGH LEVEL IN REMOTE THROTTLE SENSOR SYSTEM)
SERVICE CODE[EC134](ABNORMALLY LOW LEVEL IN REMOTE SENSOR SYSTEM)
SERVICE CODE[EC135](ABNORMALLY HIGH LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC141](ABNORMALLY LOW LEVEL IN ENGINE OIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC143](LOWERING OF ENGINE OIL PRESSURE)
SERVICE CODE[EC144](ABNORMALLY HIGH LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM)
SERVICE CODE[EC145](ABNORMALLY LOW LEVEL IN ENGINE COOLANT TEMPERATURE SENSOR SYSTEM)
SERVICE CODE[EC151](RISE OF ENGINE COOLANT TEMPERATURE)
SERVICE CODE[EC153](ABNORMALLY HIGH LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM)
SERVICE CODE[EC154](ABNORMALLY LOW LEVEL IN AIR INTAKE TEMPERATURE SENSOR SYSTEM)
SERVICE CODE[EC221](ABNORMALLY HIGH LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC222](ABNORMALLY LOW LEVEL IN ATMOSPHERIC PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC234](OVER-SPEED)
SERVICE CODE[EC254](ABNORMAL VOLTAGE OF FUEL SHUT-OFF VALVE)
SERVICE CODE[EC259](ABNORMALITY IN FUEL SHUT-OFF VALVE)
SERVICE CODE[EC261](ABNORMAL RISE OF FUEL TEMPERATURE)
SERVICE CODE[EC263](ABNORMALLY HIGH LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)
SERVICE CODE[EC265](ABNORMALLY LOW LEVEL IN FUEL TEMPERATURE SENSOR SYSTEM)
SERVICE CODE[EC316](ABNORMAL CURRENT OF FUEL PUMP ACTUATOR)
SERVICE CODE[EC318](ABNORMALITY IN FUEL PUMP ACTUATOR)
SERVICE CODE[EC346] (ABNORMALITY IN POWER-DOWN UNIT OF ENGINE CONTROLLER)
SERVICE CODE[EC384](ABNORMALITY IN PREHEATER CONTROL SYSTEM)
SERVICE CODE[EC423](ABNORMALITY IN IN-PANGE OF TIMING RAIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC441](ABNORMALLY LOW LEVEL IN BATTERY VOLTAGE SYSTEM)
SERVICE CODE[EC442](ABNORMALLY HIGH LEVEL IN BATTERY VOLTAGE SYSTEM)
SERVICE CODE[EC451](ABNORMALLY HIGH LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC452](ABNORMALLY LOW LEVEL IN FUEL RAIL PRESSURE SENSOR SYSTEM)
SERVICE CODE[EC455](ABNORMAL CURRENT OF FUEL RAIL ACTUATOR)
SERVICE CODE[EC467](ABNORMALITY IN TIMING RAIL ACTUATOR CONTROL)
SERVICE CODE[EC468](ABNORMALITY IN FUEL RAIL ACTUATOR CONTROL)
SERVICE CODE[EC514](ABNORMALITY IN FUEL RAIL ACTUATOR)
SERVICE CODE[EC554](ABNORMALITY IN IN-RANGE OF FUEL RAIL PRESSURE SENSOR SYSTEM)
TROUBLESHOOTING OF ELECTRICAL SYSTEM(E-MODE)
INFORMATION IN TROUBLESHOOTING TABLE
E-1 THE ENGINE DOES NOT START
E-2 PREHEAT DOES NOT OPERATE(MANUAL PREHEATING FUNCTION)
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
E-4 WHEN THE STARTING SWITCH IS ON, NONE OF THE MONITOR PANELS COME ON
E-5 WHEN THE STARTING SWITCH IS ON, ALL MONITOR PANELS APE KEPT COMING ON AND DO NOT COME OUT
E-6 WHEN THE STARTING SWITCH IS ON, THE BASIC CHECK ITEM FLASHES
E-7 WHEN THE ENGINE IS OPERATING,THE CAUTION ITEM FLASHES
E-8 WHEN THE ENGINE IS OPERATING,THE EMERGENCY ALARM ITEM FLASHES
E-9 THE PREHEATING LAMP DOES NOT COME ON
E-10 THE DISPLAY OF THE ENGINE WATER TEMPERATURE GAUGE IS NOT NORMAL
E-11 THE DISPLAY OF THE TORQUE CONVERTER OIL TEMPERATURE GAUGE IS NOT NORMAL
E-12 THE DISPLAY OF THE FUEL GAUGE IS NOT NORMAL
E-13 THE DISPLAY OF THE GEAR SPEED/ENGINE SPEED/SHIFT MODE IS NOT NORMAL
E-14 THE DISPLAY OF THE SERVICE METER IS NOT MORMAL
E-15 THE SWITCH MODULE CANNOT BE OPERATED
E-16 THE ALARM LAMP DOES NOT FLASH OR COME OUT
E-17 THE ALARM BUZZER DOES NOT SOUND OR STOP
E-18 THE ALARM BUZZER CANNOT BE CANCELLED
E-19 THE SERVICE MODE CANNOT BE SELECTED
E-20 BACK-UP ALAPM DOES NOT SOUND
E-21 INSTRUMENT PANEL NIGHT LAMP,HEADLAMP,WORKING LAMP AND REAR LAMP DO NOT COME ON
E-22 AIR CONDITIONER DOES NOT OPERATE
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM(H-MODE)
INFORMATION IN TROUBLESHOOTING TABLE
H-1 NO FORCE (NO DRAWBAR PULL)
H-2 NO TRAVEL (AT 2ND OR 3RD SPEED)
H-3 NO TRAVEL AT ALL GEAR SPEEDS
H-4 LARGE LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING
H-5 LARGE LAG AT GEAR SPEED SHIFTING OR FORWARD-REVERSE SHIFTING
H-6 STEERING IS NOT POSSIBLE
H-7 STEERING IS POSSIBLE ONLY ON ONE SIDE
H-8 STEERING OVERRUN OCCURS
H-9 BRAKE DOES NOT WORK
H-10 TORQUE CONVERTER IS NOT LOCK-UP
H-11 TORQUE CONVERTER OIL IS OVERHEATED
H-12 ALL WORK EQUIPMENT OPERATES SLOWLY
H-13 ALL WORK EQUIPMENT DOES NOT OPERATE
H-14 BLADE LIFT RAISING SPEED IS SLOW OR THE BLADE LIFT HAS NO POWER
H-15 BLADE TILT RAISING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-16 RIPPER LIFT RAISING SPEED IS SLOW OR THE RIPPER LIFT HAS NO POWER
H-17 RIPPER TILTING SPEED IS SLOW OR THE BLADE TILT HAS NO POWER
H-18 HYDRAULIC DRIFT OF BLADE LIFT IS LARGE
H-19 HYDRAULIC DRIFT OF BLADE TILT IS LARGE
H-20 HYDRAULIC DRIFT OF RIPPER LIFT IS LARGE
H-21 RIPPER PIN PULLER CYLINDER DOES NOT OPERATE
H-22 BLADE PITCH DOES NOT OPERATE
H-23 ABNORMAL NOISE OCCURS AROUND THE WORK EQUIPMENT PUMP
TROUBLESHOOTING OF THE ENGINE BODY(S-MODE)
POINTS TO REMEMBER WHEN TROULESHOOTING
METHOD OF USING TROUBLESHOOTING CHARTS
S-1 STARTING PERFORMANCE IS POOR(STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
1) ENGINE DOES NOT TURN
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START(FUEL ID BEING INJECTED)
S-3 ENGINE DOES NOT PICK UP SMOOTHLY(FOLLOW-UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING)
S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)
S-7 EXHAUST SMOKE IS BLACK(INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER ,OR WATER SPURTS BACK ,OR WATER LEVEL GOES DOWN
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE

30 DISASSEMBLY AND ASSEMBLY
HOW TO READ THIS MANUAL
REMOVAL AND INSTALLATION OF ASSEMBLIES
DISASSEMBLY AND ASSEMBLY OF ASSEMBLIES
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SKETCHES OF SPECIAL TOOLS
REMOVAL AND INSTALLATION OF FUEL PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL
SPECIAL TOOLS
ROMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF DAMPER
DISASSEMBLY OF DAMPER ASSEMBLY
DISASSEMBLY OF DAMPER COVER ASSEMBLY
ASSEMBLY OF DAMPER ASSEMBLY
ASSEMBLY OF DAMPER COVER ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY
REMOVAL
INSTALLATION
DISCONNECTION OF POWER TRAIN UNIT ASSEMBLY
CONNECTION OF POWER TRAIN UNIT ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF STEERING CASE ASSEMBLY
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF POWER TRAIN,LUBRICATION PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY
SPECIAL TOOS
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
SKETCH OF SPECIAL TOOL
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY
SPECIAL TOOS
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION TRACK ROLLER ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
SKETCH OF SPECIAL TOOL
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
SKETCH OF SPECIAL TOOL
REMOVAL AND INSTALLATION OF BOGIE ASSEMBLY
SPECIAL TOOS
REMOVAL
INSTALLATION
SKETCH OF SPECIAL TOOL
DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
SKETCH OF SPECIAL TOOL
EXPANDING AND ASSEMBLY TRACK SHOE INSTALLATION
CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY
EXPANDING TRACK SHOE ASSEMBLY
EXPANDING TRACK SHOE ASSEMBLY
INATALLATION OF TRACK SHOE ASSEMBLY
WHOLE DISASSEMBLY AND ASSEMBLY OF TRACK SHOE
SPECIAL TOOLS
WHOLE DISASSEMBLY
WHOLE ASSEMBLY
1. WHEN RECYCLING FOR LUBRICATED TRACK
2. WHEN RECYCLING FOR GREASE-FILLED TRACK
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS
DISASSEMBLY AND ASSEMBLY OF 1 LINK IN FIELD
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF MASTER LINK
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
SKETCH OF SPECIAL TOOL
REMOVAL AND INSTALLATION OF EQUALIZER BAR
SPECIAL TOOLS
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
SKETCH OF SPECIAL TOOL
REMOVAL AND INSTALLATION OF SEGMENT TOOTH
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF HYDRAULIC TANK ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF WORK EQUIPMENT AND PPC PUMP ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF BLADE LIFT VALVE ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF BLADE LIFT VALVE ASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BLADE TILE AND RIPPER LOW VALVE ASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RIPPER HIGH VALVE ASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF PPC CHARGE VALVE ASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF BLADE PPC VALVE ASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RIPPER PPC VALVE ASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF RIPPER PIN PULER CYLINDER ASSEMBLY
SPECIAL TOOLS
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY AND ASSEMBLY OF BLADE ASSEMBLY
DISASSEMBLY
ASSEMBLY
DISASSEMBLY AND ASSEMBLY OF GIANT RIPPER ASSEMBLY
DISASSEMBLY
ASSEMBLY
REMOVAL AND INSTALLATION OF ROPS GUARD
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF FLOOR FRAME
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF DASHBOARD ASSEMBLY
SPECIAL TOOLS
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF MONITOR PANEL ASSEMBLY
REMOVAL
INSTALLATION
REMOVAL AND INSTALLATION OF AIR CONDITIONER UNIT ASSEMBLY
REMOVAL
INSTALLATION

90 OTHERS
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(TILTDOZER)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(TILTDOZER)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(DUAL TILTDOZER)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM(DUAL TILTDOZER)
ELECTRICAL CIRCUIT DIAGRAM(1/5)
ELECTRICAL CIRCUIT DIAGRAM(2/5)
ELECTRICAL CIRCUIT DIAGRAM(3/5)
ELECTRICAL CIRCUIT DIAGRAM(4/5)
ELECTRICAL CIRCUIT DIAGRAM(5/5)
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER
ELECTRIC CIRCUIT DIAGRAM OF INSIDE CAB
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