This Komatsu D375A-6R Crawler Dozer Shop Manual (SEN05214-21) is the workshop-level book for tearing into a big production dozer used on mining, heavy earthmoving, and large construction pads. People who reach for this kind of manual are field techs, dealer or independent shop mechanics, and sometimes fleet maintenance leads. They’re usually trying to get hard faults sorted, major components off and back on, and systems tested correctly so the machine isn’t sitting dead on a bench or a lowboy. If you’re just looking for daily checks or basic operation, this is more than you need.
What this manual helps you do
- Trace hydraulic and drivetrain faults using step-by-step diagnostic trees and machine test points.
- Check disassembly and reassembly sequences for major components like final drives, powertrain, and blade controls.
- Follow wiring and hydraulic routing diagrams to chase down shorts, open circuits, or misrouted hoses.
- Diagnose engine and electronic control issues with guided checks using a multimeter, test gauges, and laptop tools.
- Handle adjustments and post-repair verification so the D375A-6R is back within normal operating parameters before release.
Who this is for
This shop manual is aimed at field techs, shop mechanics, and fleet maintenance teams who already turn wrenches on heavy equipment. Operators or new trainees who just need basic operation and daily service would be better off with the Operation & Maintenance manual instead.
FAQ
Q: Is this a PDF I can download and search?
A: Yes, it’s a PDF you can download, search by keyword, and print sections you need in the field.
Q: Is it detailed enough for full overhauls or just light service?
A: The Komatsu D375A-6R Crawler Dozer Shop Manual walks through diagnostic procedures, disassembly sequences, and reference data used during workshop-level repairs.
Q: How do I know it matches my exact machine version?
A: Check your machine’s model tag and confirm it’s a D375A-6R, then match the book reference SEN05214-21 against what your dealer lists for that model.
Bottom line: If you’re the one actually repairing or troubleshooting a D375A-6R, this is the right manual; if you only operate or fuel the machine, you can skip it.
📘 Show Index
Table of Contents:
- 00 Index and Foreword
- Table of contents
- Foreword and general information
- Safety notice
- How to read the shop manual
- Explanation of terms for maintenance standard
- Handling of electric equipment and hydraulic components
- Handling of connectors newly used for engines
- How to read electric wire code
- Precautions when carrying out work
- Method of disassembling and connecting push-pull type coupler
- Standard tightening torque table
- List of Abbreviation
- Conversion table
- 01 Specification
- Specification and technical data
- Specification drawing
- Specifications
- Weight table
- Table of fuel, coolant and lubricants
- 10 Structure and function
- Engine and cooling system
- Cooling system
- Cooling fan pump
- Cooling fan motor
- Power train
- Power train
- Overall drawing of power train unit
- Power train hydraulic equipment arrangement drawing
- Damper and universal joint
- Torque converter and PTO
- Torque converter control valve
- Main relief valve and torque converter relief valve
- Lockup clutch ECMV and stator clutch ECMV
- Scavenging pump
- Transmission control
- PCCS lever
- Transmission
- Transmission ECMV
- Transmission lubrication relief valve
- Steering and brake control
- Transfer unit, bevel gear shaft and steering
- Steering control valve
- Steering clutch ECMV and Steering brake ECMV
- Parking brake valve
- Sudden stop prevention valve
- Final drive
- Undercarriage and frame
- Track frame
- Idler cushion
- Track roller bogie
- Main frame
- Suspension
- Hydraulic system
- Work equipment hydraulic piping diagram
- PPC control piping diagram
- Work equipment control
- Hydraulic tank
- Accumulator
- PPC lock valve
- PPC valve
- Piston valve
- Quick drop valve
- Pin puller switch
- Pin puller solenoid valve
- Blade control lever (only for the machine with dual tilt specification)
- Work equipment pump
- Control valve
- Self-pressure reducing valve
- Work equipment
- Cab
- Electrical system
- Engine control
- Engine control system
- CRI engine control system
- Monitor system
- Machine monitor
- Lamp system
- Engine preheat (electrical intake air heater) control
- Palm command control system
- Sensor
- Vehicle health monitoring system (VHMS)
- ORBCOMM system
- Pre-lubrication system
- 20 Standard value table
- Standard service value table
- Standard value table for engine
- Standard value table for machine
- 30 Testing and adjusting
- Tools for testing, adjusting and troubleshooting
- Engine and cooling system
- Testing engine speed
- Testing intake air pressure (boost pressure)
- Testing exhaust temperature
- Testing exhaust gas color
- Adjusting valve clearance
- Measuring compression pressure
- Testing blow-by pressure
- Testing engine oil pressure
- Handling of fuel system devices
- Releasing residual pressure from fuel system
- Testing fuel pressure
- Handling of reduced cylinder mode operation
- Handling of no injection cranking operation
- Testing leakage from pressure limiter and return rate from injector
- Bleeding air from fuel circuit
- Testing fuel circuit for leakage
- Replacing and adjusting alternator and air conditioner compressor belt
- Measuring fan speed
- Testing fan circuit oil pressure
- Bleeding air from fan pump
- Adjusting fuel control dial and decelerator pedal
- Power train
- Testing power train oil pressure
- Adjusting transmission output speed sensor
- Simple test procedure for brake performance
- Adjusting brake pedal and parking brake lever
- Adjusting position of pccs lever console
- Emergency escape method when there is failure in power train
- Undercarriage and frame
- Inspecting wear of sprocket
- Testing and adjusting track shoe tension
- Hydraulic system
- Testing and adjusting work equipment oil pressure
- Testing control circuit main pressure
- Testing PPC valve output pressure
- Adjusting play of PPC valve
- Testing output pressure of ripper pin-puller solenoid valve
- Checking location of cause of hydraulic drift of blade and ripper
- Testing leakage inside work equipment cylinder
- Releasing remaining pressure in work equipment cylinders
- Bleeding air from work equipment cylinders
- Adjusting ripper lever position
- Work equipment
- Adjusting work equipment lock lever
- Adjusting blade
- Cab and its attachments
- Testing and adjusting operator's cab
- Electrical system
- Special functions of machine monitor (EMMS)
- Handling of voltage circuit of engine controller
- Adjustment method when controller has been replaced
- Preparation work for troubleshooting for electrical equipment system
- Inspection procedure of diode
- Handling of optional devices
- Request for opening ORBCOMM terminal
- Initialization procedures for VHMS controller
- Using method of KOMTRAX functions of ORBCOMM terminal
- Precautions for replacing VHMS controller
- Pm Clinic
- 40 Troubleshooting
- General information on troubleshooting
- Points to remember when troubleshooting
- Sequence of events in troubleshooting
- Checks before troubleshooting
- Classification and procedures for troubleshooting
- Failure codes table
- Classification and procedures for troubleshooting numbers
- Information in troubleshooting table
- Troubleshooting method for disconnecting wiring harness of pressure sensor system
- Connection table for connector pin numbers
- T-branch box and T-branch adapter table
- Connector list and layout
- Fuse locations table
- Troubleshooting by failurecode
- Failure code [1380MW] Lock up clutch: Slip
- Failure code [1500L0] Transmission clutch: Abnormal
- Failure code [15E0MW] Transmission clutch: Slip
- Failure code [15SAL1] Forward clutch: Fill high
- Failure code [15SALH] Forward clutch: Fill Low
- Failure code [15SBL1] Reverse clutch: Fill high
- Failure code [15SBLH] Reverse clutch: Fill Low
- Failure code [15SEL1] Speed 1st clutch: Fill high
- Failure code [15SELH] Speed 1st clutch: Fill Low
- Failure code [15SFL1] Speed 2nd clutch: Fill high
- Failure code [15SFLH] Speed 2nd clutch: Fill Low
- Failure code [15SGL1] Speed 3rd clutch: Fill high
- Failure code [15SGLH] Speed 3rd clutch: Fill Low
- Failure code [15SJL1] L/U: Fill high
- Failure code [15SJLH] L/U: Fill low
- Failure code [1800MW] P/T clutch: Slip
- Failure code [2201L1] Right clutch: Fill high
- Failure code [2201LH] Right clutch: Fill low
- Failure code [2202L1] Left clutch: Fill high
- Failure code [2202LH] Left clutch: Fill low
- Failure code [2300NR] Brake Themal Load Abnormality
- Failure code [2301L1] Right brake: Fill high
- Failure code [2301LH] Right brake: Fill low
- Failure code [2301NR] Steering Brake RH Themal Load Abnormality
- Failure code [2302L1] Left brake: Fill high
- Failure code [2302LH] Left brake: Fill low
- Failure code [2302NR] Steering Brake LH Themal Load Abnormality
- Failure code [7RFAKA] ECM ACC CUT RELAY: Disconnection
- Failure code [7RFAKB] ECM ACC CUT RELAY: Short circuit
- Failure code [AA10NX] Air Cleaner Clogging
- Failure code [AB00MA] Battery Charge Abnormal
- Failure code [B@BAZG] Eng Oil Press Low
- Failure code [B@BAZK] Eng Oil Level Low
- Failure code [B@BCNS] Eng Water Overheat
- Failure code [B@BCZK] Eng Water Level Low
- Failure code [B@CENS] T/C Oil Overheat
- Failure code [B@HANS] Hyd Oil Overheat
- Failure code [B@HAZK] Hyd Oil Level Low
- Failure code [CA111] ECM Critical Internal Failure
- Failure code [CA115] Eng Ne and Bkup Speed Sens Error
- Failure code [CA122] Chg Air Press Sensor High Error
- Failure code [CA123] Chg Air Press Sensor Low Error
- Failure code [CA131] Throttle Sensor High Error
- Failure code [CA132] Throttle Sensor Low Error
- Failure code [CA135] Eng Oil Press Sensor High Error
- Failure code [CA141] Eng Oil Press Sensor Low Error
- Failure code [CA144] Coolant Temp Sens High Error
- Failure code [CA145] Coolant Temp Sens Low Error
- Failure code [CA153] Chg Air Temp Sensor High Error
- Failure code [CA154] Chg Air Temp Sensor Low Error
- Failure code [CA187] Sens Supply 2 Volt Low Error
- Failure code [CA212] Eng Oil Temp Sensor High Error
- Failure code [CA213] Eng Oil Temp Sensor Low Error
- Failure code [CA221] Ambient Press Sens High Error
- Failure code [CA222] Ambient Press Sens Low Error
- Failure code [CA227] Sens Supply 2 Volt High Error
- Failure code [CA234] Eng Overspeed
- Failure code [CA238] Ne Speed Sens Supply Volt Error
- Failure code [CA263] Fuel Temp Sensor High Error
- Failure code [CA265] Fuel Temp Sensor Low Error
- Failure code [CA271] IMV/PCV1 Short Error
- Failure code [CA272] IMV/PCV1 Open Error
- Failure code [CA273] PCV2 Short Error
- Failure code [CA274] PCV2 Open Error
- Failure code [CA322] Inj #1 (L#1) Open/Short Error
- Failure code [CA323] Inj #5 (L#5) Open/Short Error
- Failure code [CA324] Inj #3 (L#3) Open/Short Error
- Failure code [CA325] Inj #6 (L#6) Open/Short Error
- Failure code [CA331] Inj #2 (L#2) Open/Short Error
- Failure code [CA332] Inj #4 (L#4) Open/Short Error
- Failure code [CA342] Calibration Code Incompatibility
- Failure code [CA351] Injectors Drive Circuit Error
- Failure code [CA352] Sens Supply 1 Volt Low Error
- Failure code [CA386] Sens Supply 1 Volt High Error
- Failure code [CA441] Battery Voltage Low Error
- Failure code [CA442] Battery Voltage High Error
- Failure code [CA449] Rail Press Very High Error
- Failure code [CA451] Rail Press Sensor High Error
- Failure code [CA452] Rail Press Sensor Low Error
- Failure code [CA553] Rail Press High Error
- Failure code [CA554] Rail Press Sensor In Range Error
- Failure code [CA559] Rail Press Low Error
- Failure code [CA689] Eng Ne Speed Sensor Error
- Failure code [CA731] Eng Bkup Speed Sens Phase Error
- Failure code [CA757] All Continuous Data Lost Error
- Failure code [CA778] Eng Bkup Speed Sensor Error
- Failure code [CA1633] KOMNET Datalink Timeout Error
- Failure code [CA2185] Throt Sens Sup Volt High Error
- Failure code [CA2186] Throt Sens Sup Volt Low Error
- Failure code [CA2249] Rail Press Very Low Error
- Failure code [D110KB] Battery Relay: Drive Short Circuit
- Failure code [D130KA] Neutral relay: Disconnection
- Failure code [D130KB] Neutral relay: Short circuit
- Failure code [D161KA] Back-up alarm releay: Disconnection
- Failure code [D161KB] Back-up alarm releay: Short circuit
- Failure code [D182KZ] Preheater Relay Abnormality
- Failure code [D190KA] ACC signal relay: Disconnection
- Failure code [D190KB] ACC signal relay: Short circuit
- Failure code [D1EFKA] Pre lub. motor relay: Disconnection
- Failure code [D1EFKB] Pre lub. motor relay: Short circuit
- Failure code [DAFRKR] Monitor: Can communication lost (PT)
- Failure code [dAFRKR] Monitor: CAN communication lost (WE)
- Failure code [DAFRMC] CAN Discon (Monitor Detected)
- Failure code [DB2RKR] ENG cont.: Can communication lost (PT)
- Failure code [dB2RKR] ENG controller: CAN communication lost (WE)
- Failure code [DB90KT] WE controller: Abnormality in controller
- Failure code [DB91KK] WE controller: Source voltage reduction
- Failure code [DB92KK] WE controller: Output voltage reduction
- Failure code [DB97KK] WE cont.: Sensor voltage 5 V (2) reduction
- Failure code [DB99KQ] WE controller: Type select signal
- Failure code [DB9RKR] WE controller: Can communication lost (PT)
- Failure code [DBB0KK] VHMS controller:Source voltage reduction
- Failure code [DBB0KQ] VHMS connector connection abnormality
- Failure code [DBB3KK] VHMS controller: Source voltage reduction
- Failure code [DBB5KP] VHMS: Output sensor1 voltage reduction
- Failure code [DBB6KP] VHMS:Output sensor2 voltage reduction
- Failure code [DBB7KP] VHMS:Output sensor3 voltage reduction
- Failure code [DBBQKR] PT cont.: Can communication lost (VHMS)
- Failure code [DBE0KT] PT controller: Abnormality in controller
- Failure code [DBE1KK] PT controller: Source voltage reduction
- Failure code [DBE2KK] PT controller: Output voltage reduction
- Failure code [DBE5KK] PT cont.: Sensor voltage 5 V (1) reduction
- Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction
- Failure code [DBE7KK] PT cont.: Sensor voltage 5 V reduction
- Failure code [DBE9KQ] PT controller: Type select signal
- Failure code [DBERKR] PT controller: Can communication lost (WE)
- Failure code [DD12KA] Shift up Sw: Disconnection
- Failure code [DD12KB] Shift up Sw: Short circuit
- Failure code [DD13KA] Shift down Sw: Disconnection
- Failure code [DD13KB] Shift down Sw: Short circuit
- Failure code [DD14KA] Parking lever Sw: Dissconnection
- Failure code [DD14KB] Parking lever Sw: Short circuit
- Failure code [DDB9L4] Reverse SW Signal disagreement
- Failure code [DDE2KA] Pre lub. oil press sw: Disconnection
- Failure code [DDK3L4] Forward SW Signal disagreement
- Failure code [DDK5KA] Shift switch disconnection
- Failure code [DDK5KB] Shift switch short circuit
- Failure code [DDN2LD] Blade tilt RH pressure SW abnormality
- Failure code [DDN3LD] Blade tilt LH pressure SW abnormality
- Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection
- Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit
- Failure code [DDN9KA] WEQ Knob Sw (up): Disconnection
- Failure code [DDN9KB] WEQ Knob Sw (up): Short circuit
- Failure code [DDNALD] Blade lift up pressure SW abnormality
- Failure code [DDNBLD] Ripper lift up pressure SW abnormality
- Failure code [DDNCLD] Ripper lift down pressure SW abnormality
- Failure code [DDNDLD] Ripper tilt in pressure SW abnormality
- Failure code [DDNELD] Ripper tilt back pressure SW abnormality
- Failure code [DDNFLD] Blade lift down pressure SW abnormality
- Failure code [DDNLKA] Weq lock Sw: Disconnection
- Failure code [DDNLKB] Weq lock Sw: Short circuit
- Failure code [DDT5KA] Neutral switch disconnection
- Failure code [DDT5KB] Neutral switch short circuit
- Failure code [DDT5KQ] Lever SPEC selection signal disagreement
- Failure code [DDTSL1] S/C: Fill high
- Failure code [DDTSLH] S/C: Fill low
- Failure code [DGE5KX] Ambient temp sensor abnormality
- Failure code [DGS1KX] Hyd oil temp: signal abnormal
- Failure code [DGT1KA] T/C oil temp sensor: Abnormal
- Failure code [DGT1KX] T/C oil temp sensor: Abnormal
- Failure code [DGT5KA] F exhaust temp sensor disconnection
- Failure code [DGT5KB] F exhaust temp sensor short circuit
- Failure code [DGT6KA] R exhaust temp sensor disconnection
- Failure code [DGT6KB] R exhaust temp sensor short circuit
- Failure code [DH21KA] Weq pressure sensor: Disconnection
- Failure code [DH21KB] Weq pressure sensor: Short circuit
- Failure code [DHE5KB] ENG blow-by pressure sensor disconnection
- Failure code [DHE5KY] ENG blow-by pressure sensor short circuit
- Failure code [DHT3KX] T/M oil pressure sensor abnormality
- Failure code [DHT5KA] T/C in-pressure sensor: Disconnection
- Failure code [DHT5KB] T/C in-pressure sensor: Short circuit
- Failure code [DHT7KA] T/C out-pressure sensor: Disconnection
- Failure code [DHT7KB] T/C out-pressure sensor: Short circuit
- Failure code [DK10KA] Fuel control Dial: Disconnection
- Failure code [DK10KB] Fuel control Dial: Short circuit
- Failure code [DK30KA] ST lever 1: Disconnection
- Failure code [DK30KB] ST lever 1: Short circuit
- Failure code [DK30KX] ST lever: Out of normal range
- Failure code [DK30KZ] ST lever: Disconnection or short circuit
- Failure code [DK30L8] ST lever: Signal mismatch
- Failure code [DK31KA] ST lever 2: Disconnection
- Failure code [DK31KB] ST lever 2: Short circuit
- Failure code [DK40KA] Brake potentiometer: Disconnection
- Failure code [DK40KB] Brake potentiometer: Short circuit
- Failure code [DK55KX] FR lever: Out of normal range
- Failure code [DK55KZ] FR lever: Disconnection or short circuit
- Failure code [DK55L8] FR lever: Signal mismatch
- Failure code [DK56KA] FR lever 1: Disconnection
- Failure code [DK56KB] FR lever 1: Short circuit
- Failure code [DK57KA] FR lever 2: Disconnection
- Failure code [DK57KB] FR lever 2: Short circuit
- Failure code [DK60KA] Acceleration sensor: Disconnection
- Failure code [DK60KB] Acceleration sensor: Short circuit
- Failure code [DKH1KA] Pitch angle sensor: Disconnection
- Failure code [DKH1KB] Pitch angle sensor: Short circuit
- Failure code [DLF1KA] T/C out-speed sensor: Disconnection
- Failure code [DLM3KA] Fan rev. sensor: Disconnection
- Failure code [DLM3MB] Fan control: Decline
- Failure code [DLT3KA] T/M out-speed sensor: Disconnection
- Failure code [DLT3KB] T/M out-speed sensor: Abnormal
- Failure code [DW59KA] Blade dual selector SOL disconnection
- Failure code [DW59KB] Blade dual selector SOL short circuit
- Failure code [DW59KY] Blade dual selector SOL hot short
- Failure code [DW5AKA] Blade pitch selector SOL disconnection
- Failure code [DW5AKB] Blade pitch selector SOL short circuit
- Failure code [DW5AKY] Blade pitch selector SOL Short circuit
- Failure code [DW7BKA] Fan rev EPC: Disconnection
- Failure code [DW7BKB] Fan rev EPC: Short circuit
- Failure code [DWN3KA] Ssp solenoid: Disconnection
- Failure code [DWN3KB] Ssp solenoid: Short circuit
- Failure code [DWN3KY] SSP solenoid: Short circuit
- Failure code [DWN5KA] Fan pump solenoid 1: Disconnection
- Failure code [DWN5KB] Fan pump solenoid 1: Short circuit
- Failure code [DWN5KY] Fan pump solenoid 1: Short circuit
- Failure code [DWNCKA] Fan pump solenoid 2: Disconnection
- Failure code [DWNCKB] Fan pump solenoid 2: Short circuit
- Failure code [DWNCKY] Fan pump solenoid 2: Short circuit
- Failure code [DXH1KA] Lock-up ECMV: Disconnection
- Failure code [DXH1KB] Lock-up ECMV: Short circuit
- Failure code [DXH1KY] Lock-up ECMV: Short circuit
- Failure code [DXH4KA] 1st clutch ECMV: Disconnection
- Failure code [DXH4KB] 1st clutch ECMV: Short circuit
- Failure code [DXH4KY] 1st clutch ECMV: Short circuit
- Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
- Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
- Failure code [DXH5KY] 2nd clutch ECMV: Short circuit
- Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
- Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
- Failure code [DXH6KY] 3rd clutch ECMV: Short circuit
- Failure code [DXH7KA] R clutch ECMV: Disconnection
- Failure code [DXH7KB] R clutch ECMV: Short circuit
- Failure code [DXH7KY] R clutch ECMV: Short circuit
- Failure code [DXH8KA] F clutch ECMV: Disconnection
- Failure code [DXH8KB] F clutch ECMV: Short circuit
- Failure code [DXH8KY] F clutch ECMV: Short circuit
- Failure code [DXH9KA] Right clutch ECMV: Disconnection
- Failure code [DXH9KB] Right clutch ECMV: Short circuit
- Failure code [DXH9KY] Right clutch ECMV: Short circuit
- Failure code [DXHAKA] Left clutch ECMV: Disconnection
- Failure code [DXHAKB] Left clutch ECMV: Short circuit
- Failure code [DXHAKY] Left clutch ECMV: Short circuit
- Failure code [DXHBKA] Right brake ECMV: Disconnection
- Failure code [DXHBKB] Right brake ECMV: Short circuit
- Failure code [DXHBKY] Right brake ECMV: Short circuit
- Failure code [DXHCKA] Left brake ECMV: Disconnection
- Failure code [DXHCKB] Left brake ECMV: Short circuit
- Failure code [DXHCKY] Left brake ECMV: Short circuit
- Failure code [DXJBKA] S/C ECMV: Disconnection
- Failure code [DXJBKB] S/C ECMV: Short circuit
- Failure code [DXJBKY] S/C ECMV: Short circuit
- Failure code [DY2HKA] Pre lub. motor: Disconnection
- Failure code [F@BBZL] ENG blow-by pressure high level
- Failure code [F@BYNR] F exhaust temp high level (2)
- Failure code [F@BYNS] F exhaust temp high level (1)
- Failure code [F@BZNR] R exhaust temp high level (2)
- Failure code [F@BZNS] R exhaust temp high level (1)
- Troubleshooting of electrical system (E-mode)
- Information contained in troubleshooting table
- E-1 Engine does not start (starting motor does not turn)
- E-2 Preheater does not operate
- E-3 When starting switch is turned ON, machine monitor displays nothing
- E-4 When starting switch is turned ON (before starting engine), basic check item lights up
- E-5 Precaution item lights up while engine is running
- E-6 Emergency stop item lights up while engine is running
- E-7 Engine coolant temperature gauge does not indicate normally
- E-8 Fuel gauge does not indicate properly
- E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally
- E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
- E-11 Contents of display by machine monitor are different from applicable machine
- E-12 Machine monitor does not display some items
- E-13 Function switch does not work
- E-14 Operation mode does not change
- E-15 Gearshift mode does not change
- E-16 Customize function does not operate normally
- E-17 Customize memory function does not operate normally
- E-18 Alarm buzzer does not sound or does not stop
- E-19 When starting switch is turned OFF, service meter is not displayed
- E-20 Machine monitor cannot be set in service mode
- E-21 The ripper pin puller cylinder does not operate
- E-22 Horn does not sound or does not stop
- E-23 Back-up alarm does not sound or does not stop
- E-24 Fan does not reverse
- E-25 The head lamp and rear lamp do not light up
- E-26 Windshield wiper does not operate
- E-27 Window washer does not operate
- E-28 Electric priming pump does not operate or does not stop automatically
- E-29 Orbcomm terminal does not operate normally (Data are not transmitted)
- E-30 Gear cannot be shifted
- Troubleshooting of hydraulic and mechanical system (H-mode)
- Information in troubleshooting table
- List of Failure Modes and Causes
- H-1 Machine lacks power(or drawbar pull)
- H-2 Machine cannot travel (at 2nd or 3rd each speed)
- H-3 Machine cannot travel at any gear speeds
- H-4 Machine travels only in one direction, forward or reverse
- H-5 Large time lag at gear shifting or directional change
- H-6 Machine connot turn
- H-7 Machine turns only to one side
- H-8 Machine overruns at turnning
- H-9 Brake does not work
- H-10 Torque converter does not lock up
- H-11 Power train oil overheats
- H-12 All work equipment operates too slow or lacks power
- H-13 All work equipment does not operate
- H-14 Blade lift cylinder speed is too slow or lacks power
- H-15 Blade tilt cylinder speed is too slow or lacks power
- H-16 Ripper lift cylinder speed is too slow or lacks power
- H-17 Ripper tilt cylinder speed is too slow or lacks power
- H-18 Excessive hydraulic drift of blade lift cylinder
- H-19 Excessive hydraulic drift of blade tilt cylinder
- H-20 Excessive hydraulic drift of ripper lift cylinder
- H-21 Ripper pin puller cylinder does not operate (machine with giant ripper)
- H-22 Blade pitch does not work (machine with dual tilt specification)
- H-23 Abnormal noise from around work equipment pump
- H-24 Abnormal fan rotation(noise and/or vibration are abnormally large or engine overheats)
- Troubleshooting of engine (S-mode)
- Method of using troubleshooting chart
- S-1 Engine does not start easily
- S-2 Engine does not start
- S-3 Engine does not rev up smoothly (response-up is poor)
- S-4 Engine stops during operation
- S-5 Engine does not rotate smoothly (hunting)
- S-6 Engine lacks power (or output shortage)
- S-7 Exhaust smoke is black (Incomplete combustion)
- S-8 Oil is consumption is excessive(or exhaust smoke is blue)
- S-9 Engine oil becomes contaminated quickly
- S-10 Fuel consumption is excessive
- S-11 Oil mixes into coolant(coolant blows back or is reduced)
- S-12 Engine pressure monitor lights up (drop in engine oil pressure)
- S-13 Oil level rises (Coolant or fuel mixes into oil)
- S-14 Coolant temperature rises too high (overheating)
- S-15 Abnormal noise is heard
- S-16 Vibration is excessive
- S-17 Air cannot be bled from fuel circuit (when air bleeding is performed after filter is replaced or fuel is used up and then air is bled, engine does not start or it starts but stalls)
- 50 Disassembly and assembly
- General information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tool list
- Sketches of special tools
- Engine and cooling system
- Removal and installation of fuel supply pump assembly
- Removal and installation of fuel injector assembly
- Removal and installation of cylinder head assembly
- Removal and installation of radiator guard assembly
- Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)
- Removal and installation of radiator
- Removal and installation of hydraulic oil cooler
- Removal and installation of aftercooler
- Removal and installation of engine assembly
- Removal and installation of engine hood assembly
- Removal and installation of engine front seal
- Removal and installation of engine rear seal
- Removal and installation of fan drive assembly
- Removal and installation of fan motor assembly
- Removal and installation of fuel tank assembly
- Power train
- Removal and installation of damper assembly
- Disassembly and assembly of damper assembly
- Removal and installation of power train unit assembly
- Disconnection and connection of power train unit assembly
- Disassembly and assembly of PTO assembly
- Disassembly and assembly of torque converter assembly
- Disassembly and assembly of TORQFLOW transmission assembly
- Disassembly and assembly of steering case assembly
- Removal and installation of power train pump and lubrication pump assembly
- Removal and installation of scavenging pump assembly
- Removal and installation of final drive assembly
- Disassembly and assembly of final drive assembly
- Undercarriage and frame
- Removal and installation of track frame assembly
- Removal and installation of idler assembly
- Disassembly and assembly of idler assembly
- Removal and installation of recoil spring assembly
- Disassembly and assembly of recoil spring assembly
- Removal and installation of track roller assembly
- Disassembly and assembly of track roller assembly
- Removal and installation of carrier roller assembly
- Disassembly and assembly of carrier roller assembly
- Removal and installation of bogie assembly
- Disassembly and assembly of bogie assembly
- Removal and installation of first bogie assembly
- Separation and connection of track shoe assembly
- Overall disassembly and assembly of track shoe
- Link press press-fitting jig dimensions
- Disassembly and assembly of one link assembly in the field
- Disassembly and assembly of master link
- Removal and installation of pivot shaft assembly
- Removal and installation of equalizer bar
- Disassembly and assembly of equalizer bar bushing
- Removal and installation of segment tooth
- Hydraulic system
- Removal and installation of hydraulic tank assembly
- Removal and installation of work equipment pump assembly
- Removal and installation of fan pump assembly
- Removal and installation of control valve assembly
- Disassembly and assembly of control valve assembly
- Disassembly and assembly of blade PPC valve assembly
- Disassembly and assembly of ripper PPC valve assembly
- Disassembly and assembly of hydraulic cylinder assembly
- Disassembly and assembly of ripper pin puller cylinder assembly
- Work equipment
- Removal and installation of blade assembly
- Removal and installation of blade lift cylinder assembly
- Disassembly and assembly of blade assembly
- Disassembly and assembly of giant ripper assembly
- Cab and its attachments
- Removal and installation of ROPS guard
- Removal and installation of operator's cab assembly
- Removal and installation of operator's cab glass (Stuck glass)
- Removal and installation of floor frame assembly
- Removal and installation of air conditioner unit assembly
- Electrical system
- Removal and installation of transmission controller assembly and steering controller assembly
- Removal and installation of engine controller assembly
- Removal and installation of VHMS controller assembly
- Removal and installation of machine monitor assembly
- 60 Maintenance Standard
- Engine and cooling system
- Engine mount
- Cooling fan pump
- Cooling fan motor
- Power train
- Power train unit
- Damper and universal joint
- Torque converter and PTO
- Main relief valve and torque converter relief valve
- Lockup clutch ECMV and stator clutch ECMV
- Scavenging pump
- Transmission control
- Transmission
- Transmission lubricating oil relief valve
- Power train and lubrication pump
- Transfer, bevel gear shaft and steering unit
- Steering control valve
- Steering clutch ECMV and steering brake ECMV
- Parking brake valve
- Final drive
- Sprocket
- Undercarriage and frame
- Track frame
- Idler cushion
- Idler
- Track roller
- Carrier roller
- Track roller bogie
- Track shoe
- Main frame
- Suspension
- Hydraulic system
- PPC valve
- Hydraulic cylinder
- Quick drop valve
- Work equipment pump
- Control valve
- Self-pressure reducing valve
- Work equipment
- Cylinder stay
- Blade
- Cutting edge and end bit
- Ripper
- 80 Appendix
- Air conditioner
- Precautions for refrigerant
- Air conditioner component
- Configuration and function of refrigeration cycle
- Outline of refrigeration cycle
- Air conditioner unit
- Blower unit
- FRESH/RECIRC air changeover damper
- Compressor
- Condenser
- Receiver drier
- Air conditioner control panel
- Procedure for testing and troubleshooting
- Circuit diagram and arrangement of connector pins
- System diagram
- Parts and connectors layout
- Testing temperature control
- Testing FRESH/RECIC air changeover
- Testing relay
- Troubleshooting chart 1
- Troubleshooting chart 2
- Information in troubleshooting table
- Troubleshooting for power supply system (Air conditioner does not operate)
- Troubleshooting for compressor system (Air is not cooled)
- Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
- Troubleshooting for temperature control
- Troubleshooting for FRESH/RECIRC air changeover
- Troubleshooting with gauge pressure
- Connection of service tool
- Precautions for disconnecting and connecting
- Handling of compressor oil
- 90 Diagrams and Drawings
- Hydraulic diagrams and drawings
- Symbols used in hydraulic circuit diagrams
- Power train hydraulic circuit diagram
- Hydraulic circuit diagram
- Electrical diagrams and drawings
- Symbols used in electrical circuit diagrams
- Electrical circuit diagram
- Index
Komatsu
