Komatsu Bulldozer D375A-2 Shop Manual SEBM01970207 – PDF DOWNLOAD

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Komatsu Bulldozer D375A-2 Shop Manual SEBM01970207 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Bulldozer D375A-2 Shop Manual SEBM01970207 – PDF DOWNLOAD

Language : English
Pages :585
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Bulldozer D375A-2 Shop Manual SEBM01970207 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
D375A-2 16001 and up

FOREWORD
GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.

TABLE OF CONTENTS:

Komatsu Bulldozer D375A-2 Shop Manual SEBM01970207 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
D375A-2 16001 and up

COVER 1
CONTENTS 2
10 STRUCTURE AND FUNCTION 25
GENERAL 26
POWER TRAIN 27
POWER TRAIN UNIT 28
POWER TRAIN PIPING 29
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 30
DAMPER AND UNIVERSAL JOINT 31
TORQUE CONVERTER・PTO 35
TORQUE CONVERTER VALVE 39
TRANSMISSION 47
TRANSMISSION CONTROL 52
TRANSMISSION CONTROL VALVE 53
PILOT REDUCING VALVE 55
PRIORITY VALVE 56
MODULATING VALVE 57
REDUCING VALVE 60
TRANSMISSION LUBRICATION VALVE 61
SPEED, DIRECTIONAL SELECTOR VALVE 62
SCAVENGING PUMP 66
POWER TRAIN PUMP AND LUBRICATION PUMP 67
OIL STRAINER 68
POWER TRAIN OIL FILTER AND LUBRICATION OIL FILTER 69
TRANSFER, BEVEL PINION, BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 70
TRANSFER, BEVEL PINION 71
BEVEL GEAR, STEERING CLUTCH AND STEERING BRAKE 72
STEERING CONTROL 77
STEERING CONTROL VALVE 78
FINAL DRIVE 85
MAIN FRAME 88
TRACK GROUP 90
RECOIL SPRING 92
IDLER 93
TRACK ROLLER 94
CARRIER ROLLER 94
TRACK (LUBRICATION TRACK LINK) 95
SUSPENSION 96
HYDRAULIC PIPING 98
BLADE 98
VARIABLE MULTIPLE SHANK RIPPER 99
VARIABLE GIANT RIPPER100
HYDRAULIC CONTROL101
BLADE CONTROL101
RIPPER CONTROL102
HYDRAULIC CIRCUIT SYSTEM103
HYDRAULIC CIRCUIT DIAGRAM104
HYDRAULIC TANK105
HYDRAULIC PUMP106
BLADE LIFT CONTROL VALVE107
MAIN RELIEF VALVE, SHUTTLE VALVE109
BLADE TILT CONTROL AND RIPPER LOW VALVE111
RIPPER HIGH VALVE113
HYDRAULIC CYLINDER131
BLADE LIFT CYLINDER131
BLADE TILT CYLINDER131
RIPPER LIFT CYLINDER132
RIPPER TILT CYLINDER132
PIN PULLER CYLINDER133
PISTON VALVE134
QUICK DROP VALVE135
CYLINDER STAY136
SEMI-U DOZER137
RIPPER EQUIPMENT139
VARIABLE MULTIPLE SHANK RIPPER139
VARIABLE GIANT RIPPER141
WIRING DIAGRAM143
CAB ELECTRICAL CIRCUIT145
AIR CONDITIONER ELECTRICAL CIRCUIT145
EVMS146
APS CONTROL SYSTEM159
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM161
20 TESTING AND ADJUSTING164
TABLE OF STANDARD VALUES FOR ENGINE165
TABLE OF STANDARD VALUES FOR CHASSIS166
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE171
TABLE OF STANDARD VALUES FOR DUAL TILT DOZER173
TESTING AND ADJUSTING174
TESTING AND ADJUSTING TOOL LIST175
ADJUSTING VALVE CLEARANCE176
MEASURING COMPRESSION PRESSURE177
ADJUSTING FUEL INJECTION TIMING178
MEASURING TORQUE CONVERTER STALL SPEED179
MEASURING OIL PRESSURE180
BLEEDING AIR FROM HYDRAULIC CYLINDER183
ADJUSTING LINKAGE184
ADJUSTING FUEL CONTROL LINKAGE184
ADJUSTING GEAR SHIFT LEVER LINKAGE186
ADJUSTING STEERING CLUTCH LINKAGE188
ADJUSTING BRAKE PEDAL LINKAGE190
ADJUSTING BLADE CONTROL LINKAGE192
ADJUSTING RIPPER CONTROL LINKAGE194
TROUBLESHOOTING196
POINTS TO REMEMBER WHEN TROUBLESHOOTING197
SEQUENCE OF EVENTS IN TROUBLESHOOTING198
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE199
HANDLING CONNECTORS206
PREVENTING RECURRENCE OF THE SAME TROUBLE207
CHECKS BEFORE TROUBLESHOOTING208
METHOD OF USING TROUBLESHOOTING CHARTS209
RELATED ELECTRICAL CIRCUIT211
MONITOR SYSTEM211
TORQUE CONVERTER LOCK-UP SYSTEM212
PANEL SWITCH SYSTEM212
APS SYSTEM213
RELAY BOX CIRCUIT214
LOCATION OF CONNECTORS FOR TROUBLESHOOTING215
LOCATION OF CONNECTORS217
CONNECTION TABLE FOR CONNECTOR218
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL, HYDRAULIC, MECHANICAL SYSTEMS)226
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM227
H-1 BRAKES DO NOT WORK228
H-2 MACHINE DOES NOT TURN (MACHINE CAN TRAVEL ONLY IN A STRAIGHT LINE)229
H-3 MACHINE DOES NOT TURN PROPERLY230
H-4 GEAR SHIFTING IS SLOW231
H-5 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE)231
H-6 MACHINE DOES NOT MOVE (2ND, 3RD,ENGINE RUNNING)232
H-7 MACHINE DOES NOT MOVE IN ANY SPEED RANGE234
H-8 TORQUE CONVERTER OVERHEATS236
a) POWER TRAIN OVERHEATS236
b) ENGINE OVERHEATS (ABNORMAL IN COOLING SYSTEM)236
H-9 MACHINE TURNS IN ONE DIRECTION (LEVER OPERATED)238
H-10 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP239
H-11 BLADE RAISE SPEED SLOW OR LACKS POWER239
H-12 RIPPER LIFT SPEED SLOW241
H-13 EXCESSIVE HYDRAULIC DRIFT OF BLADE243
H-14 EXCESSIVE HYDRAULIC DRIFT OF RIPPER243
H-15 TORQUE CONVERTER LOCK-UP DOES NOT WORK244
H-16 PIN PULLER CYLINDER DOES NOT WORK244
TROUBLESHOOTING OF ELECTRICAL SYSTEM245
E-1 TORQUE CONVERTER LOCK-UP DOES NOT WORK (LOCK-UP PILOT LAMP DOES NOT LIGHT UP)246
E-2 ABNORMALITY IN TORQUE CONVERTER LOCK-UP DISPLAY248
a) LOCK-UP DISPLAY LAMP DOES NOT GO OUT248
b) LOCK-UP DISPLAY LIGHTS UP BUT TORQUE CONVERTER DOES NOT LOCK-UP248
E-3 FUSE NO8 FOR TORQUE CONVERTER LOCK-UP RELAY INSIDE RELAY BOX IS BLOWN249
E-4 PIN PULLER CYLINDER DOES NOT WORK (FOR GIANT RIPPER)250
E-5 PREHEATING FUSE NO11 IS BLOWN251
E-6 DEFECTIVE OPERATION OF APS252
a) EVEN WHEN PANEL PREHEATING SWITCH IS PRESSED, THE APS PILOT ON THE MONITOR PANEL DOES NOT LIGHT UP252
b) WHEN PANEL PREHEATING SWITCH IS ON , THE APS PILOT ON THE MONITOR PANEL LIGHTS UP, BUT IT DOES NOT GO OUT WITHIN THE RANGE OF 60 – 100 SECONDS254
c) APPROX 80 SECONDS AFTER PANEL PREHEATING SWITCH IS TURNED ON , APS PILOT GOES OUT, BUT STARTING PERFORMANCE IS POOR (GLOW PLUG WORKS NORMALLY)255
d) THE ENGINE CAN BE STARTED WITH THE APS, BUT WHEN THE STARTING MOTOR STOPS, THE ENGINE STOPS ALSO257
e) APS DOES NOT STOP258
E-7 EVEN WHEN THE LIGHT SWITCH IS TURNED ON, THE LAMPS DO NOT LIGHT UP260
a) HEAD LAMP SWITCH260
b) REAR LAMP SWITCH261
c) WORKING LAMP SWITCH262
E-8 EVEN WHEN THE LIGHT SWITCH IS TURNED OFF, THE LAMPS DO NOT GO OUT263
a) HEAD LAMP SWITCH263
b) REAR LAMP SWITCH263
c) WORKING LAMP SWITCH263
E-9 PANEL SWITCH DOES NOT WORK – ABNORMALITY IN PANEL SWITCH POWER SOURCE (EVEN WHEN THE SWITCH IS PRESSED, THE RED LAMP FOR THAT SWITCH DOES NOT LIGHT UP)264
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR)266
TROUBLESHOOTING OF MONITOR SYSTEM267
M-1 NO DISPLAY APPEARS ON THE MONITOR PANEL WHEN THE STARTING SWITCH IS ON268
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL STAY ON AND DO NOT GO OUT268
M-3 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHECK ITEMS SHOW ABNORMALITY269
a) ABNORMALITY IN COOLANT LEVEL269
b) ABNORMALITY IN ENGINE OIL LEVEL270
M-4 ABNORMALITY IN PREHEATING271
a) PREHEATING MONITOR DOES NOT LIGHT UP271
b) PREHEATING MONITOR STAYS LIGHTED UP271
M-5 WHEN STARTING SWITCH IS ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH272
a) CHARGE LEVEL FLASHES272
b) ENGINE OIL PRESSURE FLASHES272
c) COOLANT LEVEL FLASHES272
d) COOLANT TEMPERATURE FLASHES272
e) TOQUE CONVERTER OIL TEMPERATURE FLASHES273
f) HYDRAULIC OIL TEMPERATURE FLASHES273
M-6 ABNORMALITY IN BUZZER 276
a) CAUTION ITEMS ARE FLASHING, BUT BUZZER DOES NOT SOUND276
b) NO ABNORMAL DISPLAY IS GIVEN ON MONITOR, BUT BUZZER SOUND276
M-7 ABNORMALITY IN WARNING LAMP 277
a) CAUTION ITEMS ARE FLASHING, BUT LAMPS DO NOT FLASH277
b) NO ABNORMAL DISPLAY IS GIVEN ON MONITOR, BUT LAMP LIGHTS UP277
M-8 ABNORMALITY IN GAUGE278
a) ABNORMALITY IN COOLANT TEMPERATURE GAUGE278
b) ABNORMALITY IN TORQUE CONVERTER OIL TEMPERATURE GAUGE279
c) ABNORMALITY IN FUEL LEVEL GAUGE280
M-9 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED281
M-10 PANEL LIGHTING FOR MONITOR PANEL DOES NOT LIGHT UP (LIQUID CRYSTAL DISPLAY IS NORMAL)282
30 DISASSEMBLY AND ASSEMBLY283
METHOD OF USING MANUAL285
PRECAUTIONS WHEN CARRYING OUT OPERATION286
SPECIAL TOOL LIST288
WEIGHT TABLE295
LUBRICANT AND COOLANT TABLE297
TIGHTENING TORQUES AND STANDARD VALUES TABLE298
STARTING MOTOR309
REMOVAL AND INSTALLATION309
ALTERNATOR310
REMOVAL AND INSTALLATION310
ENGINE OIL COOLER311
REMOVAL AND INSTALLATION311
TORQUE CONVERTER COOLER312
REMOVAL AND INSTALLATION312
FUEL INJECTION PUMP313
REMOVAL AND INSTALLATION313
WATER PUMP314
REMOVAL AND INSTALLATION314
TURBOCHARGER315
REMOVAL AND INSTALLATION315
AFTERCOOLER CORE316
REMOVAL AND INSTALLATION316
NOZZLE HOLDER317
REMOVAL AND INSTALLATION317
CYLINDER HEAD318
REMOVAL318
INSTALLATION321
FUEL TANK322
REMOVAL AND INSTALLATION322
RADIATOR AND FRONT GUARD323
TURNING OVER AND INSTALLATION323
RADIATOR324
REMOVAL AND INSTALLATION324
RADIATOR GUARD325
REMOVAL325
INSTALLATION327
ENGINE328
REMOVAL328
INSTALLATION331
DAMPER332
REMOVAL332
INSTALLATION333
DISASSEMBLY AND ASSEMBLY336
POWER TRAIN UNIT340
REMOVAL340
INSTALLATION342
PTO, TORQUE CONVERTER343
REMOVAL343
INSTALLATION345
DISCONNECTION346
CONNECTION347
TORQUE CONVERTER348
DISASSEMBLY348
ASSEMBLY352
PTO357
DISASSEMBLY357
ASSEMBLY360
TORQFLOW TRANSMISSION364
REMOVAL AND INSTALLATION364
DISASSEMBLY365
ASSEMBLY380
STEERING CASE397
DISASSEMBLY397
ASSEMBLY399
STEERING CLUTCH, BRAKE403
DISASSEMBLY403
ASSEMBLY407
TRANSFER GEAR HOUSING411
DISASSEMBLY411
ASSEMBLY413
TORQUE CONVERTER VALVE416
REMOVAL AND INSTALLATION416
DISASSEMBLY417
ASSEMBLY419
TRANSMISSION CONTROL VALVE421
REMOVAL AND INSTALLATION421
DISASSEMBLY422
ASSEMBLY424
STEERING CONTROL VALVE428
REMOVAL AND INSTALLATION428
DISASSEMBLY AND ASSEMBLY429
POWER TRAIN PUMP431
REMOVAL AND INSTALLATION431
SCAVENGING PUMP431
REMOVAL AND INSTALLATION431
FINAL DRIVE432
REMOVAL AND INSTALLATION432
DISASSEMBLY433
ASSEMBLY438
TRACK FRAME445
REMOVAL445
INSTALLATION446
RECOIL SPRING447
REMOVAL 447
INSTALLATION451
DISASSEMBLY AND ASSEMBLY452
IDLER454
REMOVAL AND INSTALLATION454
TRACK ROLLER455
REMOVAL AND INSTALLATION455
CARRIER ROLLER456
REMOVAL AND INSTALLATION456
TRACK SHOE457
CHECKING BEFORE REMOVAL457
REMOVAL (NORMAL)457
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)458
INSTALLATION459
OVERALL DISASSEMBLY460
OVERALL ASSEMBLY465
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS479
FIELD DISASSEMBLY OF ONE LINK480
FIELD ASSEMBLY OF ONE LINK482
DISASSEMBLY OF MASTER LINK484
ASSEMBLY OF MASTER LINK486
PIVOT SHAFT489
REMOVAL AND INSTALLATION489
EQUALIZER BAR490
REMOVAL490
INSTALLATION491
EQUALIZER BAR BUSHING494
REMOVAL494
INSTALLATION495
IDLER YOKE CARTRIDGE497
REMOVAL AND INSTALLATION497
IDLER PAD498
REMOVAL AND INSTALLATION498
HYDRAULIC PUMP499
REMOVAL AND INSTALLATION499
BLADE LIFT VALVE500
REMOVAL AND INSTALLATION500
DISASSEMBLY501
ASSEMBLY503
BLADE TILT, RIPPER LOW VALVE505
REMOVAL AND INSTALLATION505
DISASSEMBLY506
ASSEMBLY508
RIPPER HIGH VALVE510
REMOVAL AND INSTALLATION510
DISASSEMBLY511
ASSEMBLY513
BLADE LIFT CYLINDER515
REMOVAL AND INSTALLATION515
BLADE TILT CYLINDER516
REMOVAL AND INSTALLATION516
RIPPER LIFT CYLINDER517
REMOVAL AND INSTALLATION517
RIPPER TILT CYLINDER518
REMOVAL AND INSTALLATION518
HYDRAULIC CYLINDER519
DISASSEMBLY519
ASSEMBLY521
PIN PULLER CYLINDER523
REMOVAL AND INSTALLATION523
DISASSEMBLY AND ASSEMBLY524
WORK EQUIPMENT525
REMOVAL525
INSTALLATION526
DISASSEMBLY527
ASSEMBLY528
RIPPER529
DISASSEMBLY529
ASSEMBLY530
ROPS CAB531
TURNING OVER531
INSTALLATION532
40 MAINTENANCE STANDARD533
ENGINE MOUNT534
DAMPER AND UNIVERSAL JOINT535
TORQUE CONVERTER537
TORQUE CONVERTER VALVE539
TRANSMISSION541
TRANSMISSION CONTROL VALVE543
SPEED AND F-R VALVE545
POWER TRAIN AND LUBRICATING PUMP546
TRANSFER AND BEVEL PINION547
BEVEL GEAR SHAFT, STEERING CLUTCH AND STEERING BRAKE548
STEERING CONTROL VALVE550
FINAL DRIVE552
MAIN FRAME554
TRACK FRAME556
RECOIL SPRING557
IDLER558
TRACK ROLLER560
CARRIER ROLLER562
TRACK SHOE564
EQUALIZER BAR566
PIVOT SHAFT568
HYDRAULIC PUMP569
BLADE LIFT CONTROL VALVE570
MAIN RELIEF VALVE AND SHUTTLE VALVE571
BLADE TILT CONTROL AND RIPPER LOW VALVE572
RIPPER HIGH VALVE573
HYDRAULIC CYLINDER574
BLADE LIFT CYLINDER574
BLADE TILT AND RIPPER CYLINDER575
PIN PULLER CYLINDER576
QUICK DROP VALVE577
CYLINDER STAY578
SEMI-U DOZER579
CUTTING EDGE AND END BIT581
RIPPER EQUIPMENT582
VARIABLE MULTIPLE SHANK RIPPER582
VARIABLE GIANT RIPPER584

IMAGES PREVIEW OF THE MANUAL:

S.M 25/12/24