SEN05214-02
BULLDOZER
D375A -6R SERIAL NUMBERS
65001
and up
D375A-6R SEN0521402-00
0-1
BULLDOZER D375A-6R Shop Manual
Machine model
Serial number
D375A-6R
65001 and up
00 Index and foreword
D375A-6R
0-1
0 -1
00-1
Shop Manual Table of contents
Table of contents
0 -2
Notice of revision ....................................................................................................................
1
00 Index and Foreword Table of contents .................................................................................................................... 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 ..................................................................................................................
00 00 00 00 00 00 00 00 00 00 00 00 00 00 -
01 Specification Specification and technical data ............................................................................................. Specification drawing ........................................................................................................... Specifications....................................................................................................................... Weight table ......................................................................................................................... Table of fuel, coolant and lubricants ....................................................................................
01 - 3 01 - 3 01 - 4 01 - 9 01 - 11
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..............................................................................................
10- 4 10- 4 10- 7 10- 28 10- 34 10- 34 10- 36 10- 38 10- 40 10- 42 10- 48 10- 50 10- 52 10- 57 10- 58 10- 60 10- 64 10- 78 10- 83 10- 84 10- 86 10- 92 10- 94 10- 102 10- 103
00-2
2 2 5 5 10 12 14 23 26 29 32 35 39 43
D375A-6R (01)
Shop Manual Table of contents
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...................................................................................................................... Cylinder stay ........................................................................................................................ Cab ......................................................................................................................................... Cab mount ........................................................................................................................... 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 .............................................................................................................
10- 105 10- 110 10- 110 10- 112 10- 113 10- 114 10- 116 10- 119 10- 119 10- 123 10- 124 10- 126 10- 128 10- 129 10- 130 10- 142 10- 143 10- 145 10- 146 10- 148 10- 150 10- 162 10- 187 10- 194 10- 194 10- 195 10- 195 10- 196 10- 198 10- 198 10- 199 10- 208 10- 210 10- 212 10- 230 10- 231 10- 232 10- 235 10- 241 10- 247
20 Standard value table Standard service value table .................................................................................................. 20Standard value table for engine........................................................................................... 20Standard value table for machine ........................................................................................ 2030 Testing and adjusting Tools for testing, adjusting and troubleshooting ..................................................................... Diagnosis equipment list...................................................................................................... Engine and cooling system ..................................................................................................... Testing engine speed .......................................................................................................... Testing intake air pressure (boost pressure) ....................................................................... Testing exhaust temperature ............................................................................................... Testing exhaust gas color.................................................................................................... D375A-6R (01)
3 3 4
30- 4 30- 4 30- 6 30- 6 30- 9 30- 11 30- 14 00-3
Shop Manual Table of contents
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 .......................................................................... 00-3-1
30- 16 30- 18 30- 21 30- 23 30- 24 30- 25 30- 26 30- 27 30- 28 30- 29 30- 32 30- 34 30- 35 30- 36 30- 37 30- 38 30- 39 30- 42 30- 42 30- 56 30- 57 30- 58 30- 61 30- 62 30- 64 30- 64 30- 65 30- 66 30- 66 30- 69 30- 70 30- 72 30- 73 30- 74 30- 75 30- 76 30- 77 30- 78 30- 80 30- 80 30- 81 30- 84 30- 84 30- 90 30- 90 30- 148 30- 149 30- 153 30- 157 30- 158 30- 159 30- 161 30- 175 30- 178 D375A-6R (01)
Shop Manual Table of contents
Pm Clinic................................................................................................................................. 30- 184 Pm Clinic service ................................................................................................................. 30- 184 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 .......................................................................... D375A-6R (01)
40- 10 40- 10 40- 11 40- 12 40- 37 40- 40 40- 50 40- 52 40- 54 40- 57 40- 93 40- 96 40- 110 40- 114 40- 114 40- 115 40- 116 40- 118 40- 120 40- 122 40- 124 40- 126 40- 128 40- 130 40- 132 40- 134 40- 136 40- 138 40- 140 40- 142 40- 144 40- 146 40- 148 40- 150 40- 152 40- 154 40- 156 40- 158 40- 160 40- 162 40- 164 40- 166 40- 168 40- 170 40- 172 40- 173 40- 174 40- 175 40- 176 40- 177 00-3-2
Shop Manual Table of contents
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............................................................... 00-3-3
40- 178 40- 179 40- 180 40- 182 40- 184 40- 186 40- 188 40- 190 40- 192 40- 194 40- 196 40- 198 40- 200 40- 202 40- 204 40- 206 40- 208 40- 210 40- 212 40- 214 40- 215 40- 216 40- 218 40- 220 40- 222 40- 223 40- 224 40- 225 40- 226 40- 228 40- 230 40- 232 40- 234 40- 236 40- 238 40- 239 40- 240 40- 242 40- 243 40- 244 40- 245 40- 246 40- 248 40- 250 40- 251 40- 252 40- 256 40- 258 40- 259 40- 260 40- 262 40- 263 40- 264 40- 265 D375A-6R (01)
Shop Manual Table of contents
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 .......................................... D375A-6R (01)
40- 266 40- 268 40- 270 40- 272 40- 274 40- 276 40- 278 40- 280 40- 282 40- 284 40- 286 40- 287 40- 288 40- 294 40- 298 40- 299 40- 300 40- 302 40- 304 40- 306 40- 307 40- 310 40- 312 40- 313 40- 316 40- 318 40- 320 40- 322 40- 323 40- 324 40- 326 40- 328 40- 330 40- 332 40- 334 40- 335 40- 338 40- 340 40- 342 40- 344 40- 346 40- 348 40- 350 40- 352 40- 354 40- 356 40- 358 40- 360 40- 362 40- 364 40- 366 40- 368 40- 370 40- 372 00-3-4
Shop Manual Table of contents
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 ...................................................................... 00-3-5
40- 374 40- 376 40- 378 40- 380 40- 382 40- 384 40- 386 40- 388 40- 390 40- 392 40- 394 40- 396 40- 398 40- 400 40- 402 40- 404 40- 406 40- 408 40- 410 40- 412 40- 414 40- 416 40- 418 40- 420 40- 422 40- 424 40- 426 40- 428 40- 430 40- 432 40- 434 40- 436 40- 438 40- 440 40- 441 40- 442 40- 444 40- 446 40- 448 40- 450 40- 452 40- 453 40- 454 40- 456 40- 458 40- 460 40- 462 40- 464 40- 466 40- 468 40- 470 40- 472 40- 474 40- 476 D375A-6R (01)
Shop Manual Table of contents
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.................................................. D375A-6R (01)
40- 477 40- 478 40- 479 40- 480 40- 482 40- 484 40- 485 40- 486 40- 488 40- 489 40- 490 40- 492 40- 494 40- 496 40- 498 40- 500 40- 502 40- 504 40- 506 40- 508 40- 509 40- 510 40- 512 40- 514 40- 516 40- 518 40- 520 40- 522 40- 524 40- 526 40- 528 40- 530 40- 532 40- 534 40- 536 40- 538 40- 540 40- 542 40- 544 40- 546 40- 548 40- 550 40- 552 40- 554 40- 556 40- 558 40- 560 40- 562 40- 564 40- 566 40- 567 40- 568 40- 570 40- 572 00-3-6
Shop Manual Table of contents
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 .................................................... 00-3-7
40- 573 40- 574 40- 575 40- 576 40- 578 40- 578 40- 580 40- 584 40- 588 40- 592 40- 594 40- 596 40- 597 40- 598 40- 600 40- 601 40- 602 40- 602 40- 602 40- 603 40- 603 40- 604 40- 604 40- 605 40- 605 40- 605 40- 606 40- 608 40- 610 40- 612 40- 613 40- 622 40- 630 40- 638 40- 640 40- 642 40- 644 40- 644 40- 646 40- 648 40- 650 40- 651 40- 653 40- 654 40- 655 40- 656 40- 657 40- 658 40- 659 40- 660 40- 661 40- 662 40- 663 40- 664 D375A-6R (01)
Shop Manual Table of contents
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 ............................................................... 50How to read this manual ...................................................................................................... 50Coating materials list ........................................................................................................... 50Special tool list..................................................................................................................... 50Sketches of special tools ..................................................................................................... 50Engine and cooling system ..................................................................................................... 50Removal and installation of fuel supply pump assembly ..................................................... 50Removal and installation of fuel injector assembly .............................................................. 50Removal and installation of cylinder head assembly ........................................................... 50Removal and installation of radiator guard assembly .......................................................... 50Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler)50Removal and installation of radiator .................................................................................... 50Removal and installation of hydraulic oil cooler................................................................... 50Removal and installation of aftercooler................................................................................ 50Removal and installation of engine assembly...................................................................... 50Removal and installation of engine hood assembly............................................................. 50Removal and installation of engine front seal ...................................................................... 50Removal and installation of engine rear seal....................................................................... 50Removal and installation of fan drive assembly................................................................... 50Removal and installation of fan motor assembly ................................................................. 50Removal and installation of fuel tank assembly ................................................................... 50Power train.............................................................................................................................. 50Removal and installation of damper assembly .................................................................... 50D375A-6R (01)
4 4 6 9 17 25 25 30 35 50 55 60 62 63 64 71 74 76 80 82 84 86 86 00-3-8
Shop Manual Table of contents
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........................................................................ 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 floor frame assembly ............................................................... Removal and installation of air conditioner unit assembly ...................................................
00-3-9
50- 90 50- 93 50- 99 50- 108 50- 114 50- 123 50- 150 50- 166 50- 167 50- 168 50- 170 50- 183 50- 183 50- 188 50- 189 50- 193 50- 198 50- 200 50- 203 50- 206 50- 207 50- 211 50- 216 50- 218 50- 223 50- 227 50- 244 50- 245 50- 250 50- 254 50- 255 50- 259 50- 261 50- 262 50- 262 50- 265 50- 269 50- 271 50- 273 50- 278 50- 281 50- 283 50- 291 50- 294 50- 294 50- 296 50- 300 50- 303 50- 303 50- 304 50- 308 50- 313
D375A-6R (01)
Shop Manual Table of contents
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 ..................................................................................................... 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 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 ..................................................................................................................................
60- 3 60- 3 60- 5 60- 12 60- 14 60- 14 60- 16 60- 19 60- 22 60- 23 60- 24 60- 25 60- 26 60- 31 60- 32 60- 34 60- 40 60- 41 60- 42 60- 43 60- 46 60- 48 60- 48 60- 50 60- 52 60- 54 60- 56 60- 57 60- 58 60- 62 60- 64 60- 68 60- 68 60- 74 60- 77 60- 78 60- 81 60- 94 60- 97 60- 97 60- 98 60- 102 60- 104
80 Appendix Air conditioner ......................................................................................................................... 80D375A-6R (01)
3
00-3-10
Shop Manual Table of contents
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 ..................................................................................................
808080808080808080808080808080808080808080808080808080808080-
3 4 6 7 10 14 15 16 17 18 20 22 24 26 28 32 33 34 36 38 40 42 44 48 54 56 58 60 62 64
90 Diagrams and Drawings Hydraulic diagrams and drawings........................................................................................... Symbols used in hydraulic circuit diagrams ......................................................................... Power train hydraulic diagrams and drawings ..................................................................... Hydraulic circuit diagram...................................................................................................... Electrical diagrams and drawings ........................................................................................... Symbols used in electrical circuit diagrams ......................................................................... Electrical circuit diagram ......................................................................................................
90- 3 90- 3 90- 5 90- 7 90- 11 90- 11 90- 15
Index .......................................................................................................................................
1
00-4
D375A-6R (01)
Forword and general information Safety notice
Forword and general information
0 -5
Safety notice
0 -5 (Rev. 2010/02)
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 Komatsu.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 attention 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 extreme danger.Read and understand what is described in the Operation and Maintenance Manual before operating the machine.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 precautions, 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 hitting parts with a hammer q Always wear safety glasses when grinding 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 operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification.
D375A-6R
6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly 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 condition. 9) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signals Prohibition of operation and handling by unli5 censed workers 6 Safety check before starting work Wearing protective goggles(for cleaning or grind7 ing work) Wearing shielding goggles and protectors(for 8 welding work) 9 Good physical condition and preparation Precautions against work which you are not used 10 to or you are used to too much
00-5
Forword and general information Safety notice
2. Preparation work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning tag on them. 3) When disassembling or assembling, support the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing components of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug,loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane.
00-6
6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wiring. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electrical parts, in particular. 10)Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be damaged by contact with other parts when the machine is operated. 11)When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In addition, check that connections of them are correct. 12)When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate violently or rotate at high speeds, be particularly careful to check that they are installed correctly. 13)When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14)When measuring hydraulic pressure, check that the measuring tools are correctly installed. 15)Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16)If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accordingly, open the windows and doors to ventilate well.
D375A-6R
Forword and general information Safety notice
4. Precautions for slinging work and making signals 1) Only one appointed worker must make signals and co-workers must communicate with each other frequently. The appointed signaler must make specified signals clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The signaler must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, It may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60 °, as a rule. Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allowable load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120 °. If the 2 ropes sling a 19.6 kN {2,000 kg } load at a lifting angle of 150 ° , each of them is subjected to a force as large as 39.2 kN {4,000 kg}.
D375A-6R
8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper material to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10)Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle portion.
11)Do not use twisted or kinked wire ropes. 12)When lifting up a load, observe the following. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condition of the slung load, wire ropes, and pads.
00-7
Forword and general information Safety notice
If the load is unstable or the wire rope or chains are twisted, lower the load and lift it up again. q Do not lift up the load at an angle. 13)When lowering a load, observe the following. q When lowering a load, stop it temporarily at 30 cm above the floor, and then lower it slowly. q Check that the load is stable, and then remove the sling. q Remove kinks and dirt from the wire ropes and chains used for the sling work, and put them in the specified place. q
5. Precautions for using mobile crane a Read the Operation and Maintenance Manual of the crane carefully in advance and operate the crane safely. 6. Precautions for using overhead traveling crane k A hoist crane or similar device must be used for lifting a heavy load (25 kg or more).The weight of a part that is 25 kg or more is indicated with the symbol "4" in "Disassembly and assembly". 1) Before starting work, inspect the wire ropes, brake, clutch, controller, rails, over wind stop device, ground fault circuit interrupter, crane collision prevention device, and power application warning lamp, and check safety. 2) Observe the signals for sling work. 3) Operate the hoist at a safe place. 4) Check the direction indicator plates (east, west, south, and north) and the directions of the control buttons without fail. 5) Do not sling a load at an angle. Do not move the crane while the slung load is swinging. 6) Do not raise or lower a load while the crane is moving longitudinally or laterally. 7) Do not drag a sling. 8) When lifting up a load, stop it just after it leaves the ground and check safety, and then lift it up. 9) Consider the travel route in advance and lift up a load to a safe height. 10)Place the control switch on a position where it will not be an obstacle to work and passage. 11)After operating the hoist, do not swing the control switch. 12)Remember the position of the main switch so that you can turn off the power immediately in an emergency.
00-8
13)If the hoist stops because of a power failure, turn the power switch OFF. When turning on a switch which was turned OFF by the ground fault circuit interrupter, check that the devices related to that switch are not in operation state. 14)If you find an obstacle around the hoist, stop the operation. 15)After finishing the work, stop the hoist at the specified position and raise the hook to at least 2 mabove the floor. Do not leave the sling installed to the hook. 7. Selecting wire ropes 1) Select adequate ropes depending on the weight of parts to be hoisted, referring to the table below Wire ropes (Standard "Z" twist ropes without galvanizing) (JIS G3525, No. 6, Type 6X37-A) Nominal diameter Allowable load of rope mm kN ton 10 8.8 0.9 12 12.7 1.3 14 17.3 1.7 16 22.6 2.3 18 28.6 2.9 20 35.3 3.6 25 55.3 5.6 30 79.6 8.1 40 141.6 14.4 50 221.6 22.6 60 318.3 32.4
a The allowable load is one-sixth of the breaking strength of the rope used (Safety coefficient: 6).
D375A-6R
Forword and general information Safety notice
8. Precautions for disconnecting and connecting hoses and tubes in an air conditioner circuit 1) Disconnection k Although the refrigerant (refrigerant gas: R134a) used on the machine's air conditioner is less destructive to the ozone layer for environmentally friendliness, it is not allowed to be vented into the atmosphere as is.Whenever disconnecting the air conditioner gas circuit, be sure to recover the refrigerant gas to reuse it. a Ask a gualified person for collecting and filling operation of refrigerant (R134a). a Never release the refrigerant (R134a) to the atmosphere. k If the refrigerant gas gets in your eyes or contacts your skin, you may lose your sight or your skin may be frozen.Whenever recovering or adding refrigerant gas, you must put on safety glasses, safety gloves and long sleeved clothes. The refrigerant gas must be recovered and added by a qualified person.
a For tightening torque, see the precautions for installation in each section of "Disassembly and assembly".
2) Connection 1] When installing the air conditioner circuit hoses and tubes, take care to prevent dirt and water from entering into them. 2] Make sure that before installing the air conditioner hoses or tubes the O-rings (1) are fitted to their joints. 3] Check that each O-ring (1) is not damaged or deteriorated. 4] When connecting the refrigerant piping, coat the O-ring (1) with the compressor oil (Denso: ND-OIL8 or Valeo Thermal Systems Japan Corp.: ZXL100PG (PAG46 or the equivalent) for the refrigerant (R134a). a Example of O-ring (Fitted to every joint of hoses and tubes)
D375A-6R
00-9
Forword and general information How to read the shop manual
How to read the shop manual
0 -10 (Rev. 2010/02)
q q q
Some attachments and optional parts in this shop manual may not be delivered to certain areas. If one of them is required, consult KOMATSU distributors. Materials and specifications are subject to change without notice. Shop manuals are divided into the "Chassis volume" and "Engine volume". For the engine unit, see the engine volume of the engine model mounted on the machine.
1. Composition of shop manual This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections. 00. Index and foreword This section contains the index, foreword and safety and basic information.If any revision is made, the LIST OF REVISED PAGES will be added. 01. Specification This section explains the specifications of the machine. 10. Structure and function This section explains the structure and function of each component.It serves not only to give an understanding for the structure of each component, but also serves as reference material for troubleshooting. 20. Standard value table This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting. 30. Testing and adjusting This section explains measuring instruments and measuring methods for testing and adjusting, as well as the adjusting method of each part.The standard values and judgment criteria for "Testing and adjusting" are explained in standard value table. 40. Troubleshooting This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The "S mode" of the troubleshooting related to the engine may be also explained in the Chassis volume and Engine volume. In this case, see the Chassis volume. 50. Disassembly and assembly This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them.In addition, tightening torque, and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained. 60. Maintenance standard This section gives maintenance standard values of each component. The maintenance standard sub-section explains the criteria and remedies for disassembly and service. 80. Appendix This section explains the structure, function, testing, adjusting, and troubleshooting for the equipment not classifiable in other sections. 90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume) q Chassis volume This section gives hydraulic circuit diagrams and electrical circuit diagrams. q Engine volume This section explains the method of remanufacturing and repairing engine and replacing parts. 00-10
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Forword and general information How to read the shop manual
2. Revision and distribution Any additions, revisions, or other change of notices will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. 3. Filing method
File the revised or added pages in the correct order of the page numbers printed in the LIST OF REVISED PAGES. q
Revision number
When a manual is revised, revision number of each page is increased by 1. (Example: (01), (02), (03)...) q
Revisions
The revised pages are shown in the LIST OF REVISED PAGES. 4.Symbols
Important safety and quality portions are marked with the following symbols so that the shop manual will be used practically. Symbol
Item
k
Safety
Special safety precautions are necessary when performing work.
a
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing work.
4
Weight
Weight of parts of component or parts. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
3
Remarks
Tightening torque Places that require special attention for tightening torque during assembly.
2
Coat
5
Oil, coolant
6
Drain
Places to be coated with adhesives, etc. during assembly.
Places where oil, etc. must be added, and capacity.
Places where oil, etc. must be drained, and quantity to be drained.
5. Units
In this shop manual, the units are indicated with International System of units (SI). For reference, conventionally used Gravitational System of units is indicated in parentheses { }.
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Forword and general information Explanation of terms for maintenance standard
Explanation of terms for maintenance standard
0 -12
(Rev. 2010/02) The maintenance standard chapter explains the criteria for replacing or reusing products and parts in the machine maintenance work. The following terms are used to explain the criteria. 1. Standard dimension and tolerance q To be accurate, the finishing size of parts is a little different from one to another. q To specify a finishing size of a part, a temporary standard size is set and an allowable difference from that size is indicated. q The above size set temporarily is called the "standard size" and the range of difference from the standard size is called the "tolerance". q The tolerance with the symbols of + or – is indicated on the right side of the standard size. Example: Standard size
Tolerance -0.022 -0.126
120
a The tolerance may be indicated in the text and a table as [standard size (upper limit of tolerance/lower limit of tolerance)]. Example) 120 (–0.022/–0.126) Usually, the size of a hole and the size of the shaft to be fitted to that hole are indicated by the same standard size and different tolerances of the hole and shaft. The tightness of fit is decided by the tolerance. Indication of size of rotating shaft and hole and relationship drawing of them
q
q
Example: Standard size 60
Tolerance Shaft -0.030 -0.076
Hole +0.046 0
2. Standard clearance and standard value q The clearance made when new parts are assembled is called the "standard clearance", which is indicated by the range from the minimum clearance to the maximum clearance. q When some parts are repaired, the clearance is generally adjusted to the standard clearance. q A value of performance and function of new products or equivalent is called the "standard value", which is indicated by a range or a target value. q When some parts are repaired, the value of performance/function is set to the standard value.
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3. Standard interference q When the diameter of a hole of a part shown in the given standard size and tolerance table is smaller than that of the mating shaft, the difference between those diameters is called the "interference". q The range (A – B) from the difference (A) between the minimum size of the shaft and the maximum size of the hole to the difference (B) between the maximum size of the shaft and the minimum size of the hole is the "standard interference". q After repairing or replacing some parts, measure the size of their hole and shaft and check that the interference is in the standard range.
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Forword and general information Explanation of terms for maintenance standard
4. Repair limit and allowable value or allowable dimension q The size of a part changes because of wear and deformation while it is used. The limit of changed size is called the "repair limit". q If a part is worn to the repair limit, it must be replaced or repaired. q The performance and function of a product lowers while it is used. A value which the product can be used without causing a problem is called the "allowable value" or "allowable dimension". q If a product deviates from the allowable value, it must be checked or repaired. However, since most of the allowable values are estimated from various tests or experiences in most cases, it must be judged after considering the operating condition and customer's requirement. 5. Clearance limit q Parts can be used until the clearance between them is increased to a certain limit. The limit at which those parts cannot be used is called the "clearance limit". q If the clearance between the parts exceeds the clearance limit, they must be replaced or repaired. 6. Interference limit q The allowable maximum interference between the hole of a part and the shaft of another part to be assembled is called the "interference limit". q The interference limit shows the repair limit of the part of smaller tolerance. q If the interference between the parts exceeds the interference limit, they must be replaced or repaired.
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Forword and general information Handling of electric equipment and hydraulic components
Handling of electric equipment and hydraulic components
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(Rev. 2010/02) To maintain the performance of the machine over a long period, and to prevent failures or other troubles before they occur, correct "operation", "maintenance and inspection", "troubleshooting", and "repairs" must be carried out. This section deals particularly with correct repair procedures for mechatronics and is aimed at improving the quality of repairs. For this purpose, it gives sections on "Handling electric equipment" and "Handling hydraulic components" (particularly gear oil and hydraulic oil). Points to remember when handling electric equipment 1. Handling wiring harnesses and connectors Wiring harnesses consist of wires connecting one component to another component, connectors used for connecting and disconnecting one wire from another wire, and protectors or tubes used for protecting the wires. Compared with other electrical components fitted in boxes or cases, wiring harnesses are more likely to be affected by the direct effects of rain, water, heat, or vibration. Furthermore, during inspection and repair operations, they are frequently removed and installed again, so they are likely to suffer deformation or damage. For this reason, it is necessary to be extremely careful when handling wiring harnesses.
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2. Main failures occurring in wiring harness 1) Defective contact of connectors (defective contact between male and female connectors) Defective contact occurs due to improper fitting between a male and female connectors, or displacement of one or both of the connectors, or corrosion or oxidization on the contact surfaces.When poor contact resulted from a corroded or oxidized contact surfaces, you can make it shiny again (normal condition is recovered) by connecting and disconnecting the connector about 10 times. 2) Defective crimping or soldering of connectors The pins of the male and female connectors are connected to wires by crimping or soldering. If excessive force is applied to the wire, the joint is separated and causes a defective contact or the wire is broken.
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Forword and general information Handling of electric equipment and hydraulic components
3) Disconnections in wiring If the harness is pulled to disconnect the connector, or components are lifted with a crane with the harness still connected, or a heavy object hits the harness, the crimping of the connector may separate, or the soldering may be damaged, or the harness may be broken.
4) High-pressure water entering connector The connector is designed to make it difficult for water to enter (drip-proof structure), but if high-pressure water is sprayed directly on the connector, water may enter the connector, depending on the direction of the water jet. Accordingly, take care not to splash water over the connector. The connector is designed to prevent water from entering, but at the same time, if water does enter, it is difficult for it to be drained. Therefore, if water should get into the connector, the pins will be short-circuited by the water, so if any water gets in, immediately dry the connector or take other appropriate action before passing electricity through it. 5) Oil or dirt stuck to connector Since oil is not conductive, if oil or grease adheres to the connector forms an oil film on the mating surface of the male and female connectors, it cause defective contact.If adherence of oil or grease to a connector is observed, wipe it off with a dry cloth or blow it off with compressed air and then spray contact restorer to the connector. a When wiping the joint portion of the connector, be careful not to apply excessive force or deform the pins. a If oil or water is contained in the compressed air, contamination on the contacts is made worse. So remove such oil and water from the compressed air completely before starting the cleaning process.
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Forword and general information Handling of electric equipment and hydraulic components
3. Removing, installing, and drying connectors and wiring harnesses 1) Disconnecting connectors 1] Hold the connectors when disconnecting. When disconnecting a connector, hold the connector.For connectors held by a screw, loosen the screw fully, then hold the male and female connectors in each hand and pull them apart.For connectors attached with a lock stopper, press down the stopper with your thumb and pull the connectors apart. a Never pull with one hand. 2] When removing from clips q Both of the connector and clip have stoppers, which are engaged with each other when the connector is installed.
When removing a connector from a clip, pull the connector in a parallel direction to the clip for removing stoppers. a If the connector is twisted up and down or to the left or right, the housing may break.
q
3] Action to take after removing connectors After removing a connector, cover it with a vinyl bag to prevent the entry of dust, dirt, oil, or water to the contact portion. a If the machine is left disassembled for a long time, it is particularly easy for improper contact to occur, so always cover the connector.
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Forword and general information Handling of electric equipment and hydraulic components
2) Connecting connectors 1] Check the connector visually. Check that no oil, dirt, or water is stuck to connector pins (joint portion). Check that connector pins are free from deformation, defective contact, corrosion, or damage. Check that external surface of the connectors is free from damage or breakage. a If there is any oil, water, or dirt stuck to the connector, wipe it off with a dry cloth.If any water has got inside the connector, warm the inside of the connector and harness with a dryer, but be careful not to make them too hot as this will cause short circuits. a If there is any damage or breakage, replace the connector. 2] Fix the connector securely. Position the connectors correctly, and then fit them securely. For connectors with the lock stopper, push in the connector until the stopper clicks into position. 3] Correcting protrusion of the boot and misalignment of the wiring harness For connectors fitted with the fuel spray prevention caps, correct any extrusion of the caps. In addition, if the wiring harness is moved in laying, or the clamp is out of position, correct it to its right position. a If the connector cannot be corrected easily, remove the clamp and adjust the position. q If the connector clamp has been removed, be sure to return it to its original position. Check also that there are no loose clamps.
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Forword and general information Handling of electric equipment and hydraulic components
3) DT connector (DT 8-pole, 12-pole) Disconnection (Left of figure) While pressing both locks (a) and (b), pull out female connector (2). Connection (Right of figure) 1] Push in female connector (2) horizontally until the lock clicks. Arrow: 1) 2] Since locks (a) and (b) may not be set completely, push in female connector (2) while moving it up and down until the locks are set normally. Arrow: 1), 2), 3) a Right of figure: Lock (a) is pulled down (not set completely) and lock (b) is set completely. (1): Male connector (2): Female connector (a), (b): Locks
00-18
q
Disconnection
q
Connection (Example of incomplete setting of (a))
D375A-6R
Forword and general information Handling of electric equipment and hydraulic components
4) Drying wiring harness If there is any oil or dirt on the wiring harness, wipe it off with a dry cloth. Avoid washing it in water or using steam. If the connector must be washed in water, do not use high-pressure water or steam directly on the wiring harness. If water gets directly on the connector, do as follows. 1] Disconnect the connector and wipe off the water with a dry cloth. a If the connector is to be blown dry with compressed air, there is the risk that oil in the air may cause defective contact, remove oil and water in the air before starting air blow. 2] Dry the inside of the connector with a dryer. If water gets inside the connector, use a dryer to dry the connector. a Hot air from the dryer can be used, but regulate the time that the hot air is used in order not to make the connector or related parts too hot, as this will cause deformation or damage to the connector.
3] Carry out a continuity test on the connector. After drying, leave the wiring harness disconnected and carry out a continuity test to check for any short circuits between pins caused by water. a After completely drying the connector, blow it with electric contact cleaner and reassemble.
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Forword and general information Handling of electric equipment and hydraulic components
4. Handling controller 1) The controller contains a microcomputer and electronic control circuits. These control all of the electronic circuits on the machine, so be extremely careful when handling the controller. 2) Do not place objects on top of the controller. 3) Cover the control connectors with tape or a vinyl bag. Never touch the connector contacts with your hand. 4) During rainy weather, do not leave the controller in a place where it is exposed to rain. 5) Do not place the controller on oil, water, or soil, or in a place that can be heated to a high temperature even for a short time. (Place it on a suitable dry stand.) 6) Precautions when carrying out arc welding When carrying out arc welding on the machine body, disconnect all wiring harness connectors connected to the controller. Fit an arc welding ground close to the welding point.
5. Points to remember when troubleshooting electric circuits 1) Always turn the power OFF before disconnecting or connecting connectors. 2) Before carrying out troubleshooting, check all the related connectors for half fit. a Disconnect and connect the related connectors several times to check. 3) Be sure to connect any disconnected connectors before going on to the next step a If the power is turned ON with the connectors still disconnected, unnecessary abnormality warning will be issued. 4) When carrying out troubleshooting of circuits (measuring the voltage, resistance, continuity, or current), wag the related wiring harnesses and connectors several times and check that there is no change in the reading of the tester. a If there is any change, there is probably defective contact in that circuit.
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Forword and general information Handling of electric equipment and hydraulic components
Points to remember when handling hydraulic components
0 -21
With the increase in pressure and precision of hydraulic equipment, the most common cause of failure is dirt (foreign material) in the hydraulic circuit. Therefore, special precaution is required when adding hydraulic oil, or when disassembling or assembling hydraulic components. 1. Be careful of the operating environment Avoid adding hydraulic oil, replacing filters, or repairing the machine in rain or high winds, or places where there is a lot of dust. 2. Disassembly and maintenance work in the field If disassembly or maintenance work is carried out on hydraulic components in the field, there is danger of dust entering the components. It is also difficult to check the performance after repairs, so it is desirable to use unit exchange. Disassembly and maintenance of hydraulic components should be carried out in a specially prepared dustproof workshop, and the performance should be checked with special test equipment.
3. Sealing openings After any piping or equipment is removed, the openings should be sealed with caps, tapes, or vinyl bags to prevent any dirt or dust from entering. If the opening is left open or is blocked with a rag, there is danger of dirt entering or of the surrounding area being made dirty by leaking oil so never do this. Do not simply drain oil out onto the ground, but collect it and ask the customer to dispose of it, or take it back with you for disposal.
4. Preventing intrusion of foreign materials during refilling operations. Be careful not to let any dirt or dust get in when refilling with hydraulic oil.Always keep the oil filler and the area around it clean, and also use clean pumps and oil containers.If an oil cleaning device is used, it is possible to filter out the dirt that has been collected during storage, so this is an even more effective method.
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Forword and general information Handling of electric equipment and hydraulic components
5. Replacing hydraulic oil while its temperature is high When hydraulic oil or other oil is warm, it flows easily. In addition, the sludge can also be drained out easily from the circuit together with the oil, so it is best to change the oil when it is still warm. When changing the oil, as much as possible of the old hydraulic oil must be drained out. (Drain the oil from the hydraulic tank; also drain the oil from the filter and from the drain plug in the circuit.) If any old oil is left, the contaminants and sludge in it will mix with the new oil and will shorten the life of the hydraulic oil. 6. Flushing operations After disassembling and assembling the equipment, or changing the oil, use flushing oil to remove the contaminants, sludge, and old oil from the hydraulic circuit.Normally, flushing is carried out twice. Primary flushing is carried out by use of flushing oil and secondary flushing is carried out by use of the specified hydraulic oil.
7. Cleaning operations After repairing the hydraulic components (pump, control valve, etc.) or when running the machine, carry out oil cleaning to remove the sludge or contaminants in the hydraulic oil circuit. The oil cleaning components is used to remove the ultra fine (about 3 m) particles that the filter built in the hydraulic equipment cannot remove, so it is an extremely effective device.
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Forword and general information Handling of connectors newly used for engines
Handling of connectors newly used for engines a Mainly, following engines are object for following connectors. q 95E-5 q 107E-1 q 114E-3 q 125E-5 q 140E-5 q 170E-5 q 12V140E-3 Slide-lock type
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(FRAMATOME-3, FRAMATOME-2) q
95–170, 12V140 engines q Various pressure sensors and NE speed sensor Examples) Intake air pressure sensor in intake manifold: PIM (125, 170, 12V140 engines) Oil pressure sensor: POIL (125, 170, 12V140 engines) Oil pressure switch (95, 107, 114 engines) Ne speed sensor of flywheel housing: NE (95-170, 12V140 engines) Ambient pressure sensor: PAMB (125, 170, 12V140 engines)
0 -23 (Rev. 2010/02)
Pull lock type (PACKARD-2) 0 -23 q 95–170, 12V140 engines q Various temperature sensors Examples) Intake air temperature sensor in intake manifold: TIM Fuel temperature sensor: TFUEL Oil temperature sensor: TOIL Coolant temperature sensor: TWTR, etc. 0 -23 Disconnection Disconnect the connector by pulling lock (B) (on the wiring harness side) of connector (2) outward.
0 -23 Disconnection 1) Slide lock L1 to the right. 2) While pressing lock L2, pull out connector (1) toward you. a Even if lock L2 is pressed, connector (1) cannot be pulled out toward you, if part A does not float. In this case, float part A with a small screwdriver while pressing lock L2, and then pull out connector (1) toward you. Connection Insert the connector straight until it "clicks".
Connection Insert the connector straight until it "clicks".
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