Komatsu D355A-3 Bulldozer Shop Manual SEBM0195B09 PDF

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Komatsu D355A-3 Bulldozer Shop Manual SEBM0195B09 – PDF DOWNLOAD

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Komatsu D355A-3 Bulldozer Shop Manual SEBM0195B09 – PDF DOWNLOAD 

Language : English
Pages : 841
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu D355A-3 Bulldozer Shop Manual SEBM0195B09 – PDF DOWNLOAD 

COVER 1
CONTENTS 6
01 GENERAL 15
01 GENERAL 15
GENERAL 16
GENERAL VIEW 17
GENERAL ASSEMBLY DRAWING 19
SPECIFICATIONS 23
AN OVERALL VIEW OF ENGINE 27
ENGINE SPECIFICATIONS 29
WEIGHT TABLE 31
TABLE OF LUBRICANT AND WATER QUANTITY 34
LOCATION OF SERIAL NUMBERS 35
OIL AND WATER FILLING AND DRAIN POINT 37
10 ENGINE 39
11 STRUCTURE AND FUNCTION 39
STRUCTURE AND FUNCTION 40
RADIATOR 41
P T O (POWER TAKE-OFF) 43
OIL COOLER 44
ENGINE CONTROL 45
FUEL PIPING 46
12 TESTING AND ADJUSTING 47
TESTING AND ADJUSTING 48
STANDARD VALUE FOR INSPECTION AND ADJUSTMENT 49
TESTING AND ADJUSTING TOOL LIST 50
GENERAL INSTRUCTIONS FOR ENGINE INSPECTION AND ADJUSTMENT 51
MEASURING ENGINE SPEED 51
CRANKING METHOD 52
INTAKE AND EXHAUST SYSTEM 53
CHECKING AIR CLEANER ELEMENT FOR CLOGGING 53
INSPECTION OF TURBOCHARGER 54
INSPECTION AND ADJUSTMENT OF VALVE CLEARANCE 55
CHECKING EXHAUST COLOR 56
ENGINE BODY 57
MEASURING BLOW-BY 57
MEASURING COMPRESSION PRESSURE 58
LUBRICATION SYSTEM 59
CHECKING THE OIL LEVEL 59
MEASURING OIL PRESSURE AND TEMPERATURE 60
FUEL SYSTEM 61
CHECKING FUEL 61
CHECKING FUEL CONTROL LEVER POSITION 61
BLEEDING FUEL CIRCUIT 62
INSPECTION AND ADJUSTMENT OF FUEL INJECTION TIMING 62
13 DISASSEMBLY AND ASSEMBLY 64
DISASSEMBLY AND ASSEMBLY 65
DISMOUNTING OF STARTING MOTOR 66
MOUNTING OF STARTING MOTOR 67
REMOVING OF FAN BELT 68
INSTALLING OF FAN BELT 69
DISMOUNTING OF ALTERNATOR 70
MOUNTING OF ALTERNATOR 71
DISMOUNTING OF ENGINE OIL COOLER 72
MOUNTING OF ENGINE OIL COOLER 75
DISMOUNTING OF FUEL INJECTION 78
MOUNTING OF FUEL INJECTION 80
DISMOUNTING OF WATER PUMP 83
MOUNTING OF WATER PUMP 85
DISMOUNTING OF TURBOCHARGER 87
MOUNTING OF TURBOCHARGER 89
DISMOUNTING OF AFTER COOLER 91
MOUNTING OF AFTER COOLER 94
DISMOUNTING OF NOZZLE HOLDER 97
MOUNTING OF NOZZLE HOLDER 98
DISMOUNTING OF CYLINDER HEAD 99
MOUNTING OF CYLINDER HEAD 107
DISMOUNTING OF RADIATOR 116
MOUNTING OF RADIATOR 119
DISMOUNTING OF FUEL TANK 129
MOUNTING OF FUEL TANK 131
DISMOUNTING OF P T O 135
MOUNTING OF P T O 137
DISMOUNTING OF TORQUE CONVERTER OIL COOLER 139
MOUNTING OF TORQUE CONVERTER OIL COOLER 142
DISMOUNTING OF ENGINE ASSEMBLY 145
MOUNTING OF ENGINE ASSEMBLY 156
DISMOUNTING OF CHASSIS-RELATED PARTS FROM ENGINE 184
MOUNTING OF CHASSIS-RELATED PARTS ON ENGINE 186
20 POWER TRAIN 188
21 STRUCTURE AND FUNCTION 188
STRUCTURE AND FUNCTION 189
POWER TRAIN DIAGRAM 190
HYDRAULIC CIRCUIT DIAGRAM 192
HYDRAULIC CIRCUIT DIAGRAM (WITH BRAKE ASSISTER) 194
HYDRAULIC CIRCUIT DIAGRAM 196
TORQUE CONVERTER 197
TORQUE CONVERTER RELIEF VALVE 199
TORQUE CONVERTER REGULATOR VALVE 199
SCAVENGING PUMP 199
TORQFLOW TRANSMISSION 200
DISC CLUTCH 202
POWER TRAIN 203
TORQFLOW HYDRAULIC 209
TRANSMISSION LUBRICATION RELIEF VALVE 213
TRANSMISSION CONTROL VALVE 214
CONTROL VALVE SYSTEM DIAGRAM 216
PRESSURE RISE 218
MODULATING VALVE 218
SAFETY VALVE 220
TRANSMISSION PUMP 222
TRANSMISSION,STEERING OIL STRAINER 223
TRANSMISSION OIL FILTER 225
BEVEL GEAR SHAFT AND STEERING CLUTCHES 226
(1) BEVEL GEAR SHAFT 227
(2) STEERING CLUTCHES STRUCTURE 227
STEERING AND BRAKE PIPING 229
STEERING AND BRAKE HYDRAULIC SYSTEM 232
STEERING HYDRAULIC SYSTEM 233
STEERING HYDRAULIC CIRCUIT DIAGRAM 234
BRAKE HYDRAULIC SYSTEM 235
BRAKE HYDRAULIC CIRCUIT DIAGRAM 236
STEERING BRAKE AND BOOSTER 237
STEERING CONTROL VALVE 241
STEERING AND BRAKE PIPING 246
STEERING & BRAKE HYDRAULIC SYSTEM 248
STEERING & BRAKE HYDRAULIC CIRCUIT 249
STEERING BRAKE AND BOOSTER 250
STEERING CONTROL VALVE 254
STEERING MAIN RELIEF VALVE 259
STEERING BRAKE (WITH BRAKE ASSISTER) 260
BRAKE ASSISTER RELEASING METHOD 262
BRAKE ASSISTER CYLINDER FUNCTION 264
STEERING PUMP 265
STEERING OIL FILTER 266
FINAL DRIVE 267
22 TESTING AND ADJUSTING 270
TESTING AND ADJUSTING 271
OIL PRESSURE MEASURING POINTS 272
PROCEDURE FOR MEASURING OIL PRESSURE AND OIL TEMPERATURE 274
MEASURING STROKES 280
MEASURING OPERATING FORCES 281
PROCEDURE FOR ADJUSTING STROKES 284
STANDARD VALUE TABLE 287
INSPECTING BRAKE ASSISTER CYLINDER ASS’Y 291
23 DISASSEMBLY AND ASSEMBLY 292
DISASSEMBLY AND ASSEMBLY 293
DISMOUNTING OF TORQUE CONVERTER 296
MOUNTING OF TORQUE CONVERTER 299
DISASSEMBLY OF TORQUE CONVERTER 309
ASSEMBLY OF TORQUE CONVERTER 318
DISMOUNTING OF TORQUE CONVERTER RELIEF VALVE 325
MOUNTING OF TORQUE CONVERTER RELIEF VALVE 326
DISMOUNTING OF TORQUE CONVERTER REGULATOR VALVE 327
MOUNTING OF TORQUE CONVERTER REGULATOR VALVE 328
DISMOUNTING OF TORQFLOW TRANSMISSION 329
MOUNTING OF TORQFLOW TRANSMISSION 338
DISASSEMBLY OF TORQFLOW TRANSMISSION 362
ASSEMBLY OF TORQFLOW TRANSMISSION 372
DISMOUNTING OF TRANSMISSION CONTROL VALVE 397
MOUNTING OF TRANSMISSION CONTROL VALVE 398
DISASSEMBLY OF TRANSMISSION CONTROL VALVE 399
ASSEMBLY OF TRANSMISSION CONTROL VALVE 404
DISMOUNTING OF TORQFLOW TRANSMISSION LUBRICATION VALVE 409
MOUNTING OF TORQFLOW TRANSMISSION LUBRICATION VALVE 410
DISMOUNTING OF STEERING CLUTCH 411
MOUNTING OF STEERING CLUTCH 414
DISASSEMBLY OF STEERING CLUTCH 426
ASSEMBLY OF STEERING CLUTCH 428
DISMOUNTING OF BEVEL GEAR SHAFT AND BEVEL GEAR 430
MOUNTING OF BEVEL GEAR SHAFT AND BEVEL GEAR 434
DISMOUNTING OF FINAL DRIVE 1ST PINION 440
MOUNTING OF FINAL DRIVE 1ST PINION 442
DISMOUNTING OF STEERING CONTROL VALVE 445
MOUNTING OF STEERING CONTROL VALVE 446
DISASSEMBLY OF STEERING CONTROL VALVE 449
ASSEMBLY OF STEERING CONTROL VALVE 451
DISMOUNTING OF BRAKE SAFETY VALVE 455
MOUNTING OF BRAKE SAFETY VALVE 456
DISASSEMBLY OF BRAKE SAFETY VALVE 457
ASSEMBLY OF BRAKE SAFETY VALVE 458
DISASSEMBLY OF STEERING BRAKE BOOSTER 461
ASSEMBLY OF STEERING BRAKE BOOSTER 463
DISASSEMBLY OF BRAKE ASSISTER CYLINDER ASS’Y 465
ASSEMBLY OF BRAKE ASSISTER CYLINDER ASS’Y 468
DISASSEMBLY OF FINAL DRIVE 471
ASSEMBLY OF FINAL DRIVE 479
DISMOUNTING OF TRANSMISSION PUMP 488
MOUNTING OF TRANSMISSION PUMP 489
DISMOUNTING OF STEERING PUMP 490
MOUNTING OF STEERING PUMP 491
DISMOUNTING OF FLOOR FRAME 492
MOUNTING OF FLOOR FRAME 497
DISMOUNTING OF FLOOR FRAME 502
MOUNTING OF FLOOR FRAME 506
DISMOUNTING OF ROPS CAB 510
MOUNTING OF ROPS CAB 514
TILTING OF ROPS CAB 518
RETURNING ROPS CAB TO ORIGINAL POSITION 522
24 MAINTENANCE STANDARD 526
MAINTENANCE STANDARD 527
TORQUE CONVERTER (TCS46-1A K1001 AND UP) 528
(1) TORQUE CONVERTER 528
(2) RELIEF VALVE AND REGULATOR VALVE 530
TORQFLOW TRANSMISSION 531
(1) LUBRICATION RELIEF VALVE 531
(2) TRANSMISSION 532
(3) TRANSMISSION CONTROL VALVE 534
BEVEL GEAR SHAFT AND STEERING CLUTCH 536
(1) BEVEL GEAR SHAFT AND BEVEL GEAR 536
(2) STEERING CLUTCH 538
STEERING BRAKE AND BOOSTER 540
STEERING CONTROL VALVE 542
STEERING MAIN RELIEF VALVE 546
BRAKE ASSISTER AUTOMATIC DRAIN VALVE 547
BRAKE ASSISTER CHECK VALVE 548
BRAKE ASSISTER CYLINDER 549
FINAL DRIVE 550
(1) FINAL DRIVE (1/3) 550
(2) FINAL DRIVE (2/3) 552
(3) FINAL DRIVE (3/3) 554
30 UNDERCARRIAGE 555
31 STRUCTURE AND FUNCTION 555
STRUCTURE AND FUNCTION 556
TRACK (MASTER PIN TYPE) 557
TRACK (MASTER LINK TYPE) 558
TRACK FRAME 560
RECOIL SPRING 561
IDLER 562
TRACK ROLLER AND CARRIER ROLLER 563
SUSPENSION 564
33 DISASSEMBLY AND ASSEMBLY 566
DISASSEMBLY AND ASSEMBLY 567
SEPARATION OF TRACK 568
CONNECTION OF TRACK 570
DISMOUNTING OF CARRIER ROLLER 576
MOUNTING OF CARRIER ROLLER 577
DISMOUNTING OF TRACK ROLLER 578
MOUNTING OF TRACK ROLLER 580
DISMOUNTING OF IDLER 582
MOUNTING OF IDLER 584
DISMOUNTING RECOIL SPRING 586
MOUNTING OF RECOIL SPRING 589
DISASSEMBLY OF RECOIL SPRING 592
ASSEMBLY OF RECOIL SPRING 594
DISMOUNTING OF TRACK FRAME 596
MOUNTING OF TRACK FRAME 598
34 MAINTENANCE STANDARD 600
MAINTENANCE STANDARD 601
TRACK (MASTER PIN TYPE) 602
TRACK (MASTER LINK TYPE) 604
TRACK FRAME 608
RECOIL SPRING 609
IDLER 610
TRACK ROLLER 612
CARRIER ROLLER 614
60 HYDRAULIC SYSTEM 615
61 STRUCTURE AND FUNCTION 615
STRUCTURE AND FUNCTION 616
HYDRAULIC CONTROL PIPING 617
(1) BLADE SYSTEM 617
(2) VARIABLE GIANT RIPPER SYSTEM CONSISTS OF THE FOLLOWING 618
(3) VARIABLE MULTI RIPPER SYSTEM 620
WORK EQUIPMENT PUMP 622
HYDRAULIC CONTROL 623
(1) NEUTRAL 623
(2) BLADE LIFT OPERATION 625
(3) BLADE TILT OPERATION 627
(4) RIPPER LIFT OPERATION 629
(5) RIPPER TILT OPERATION 631
PIN PULLER 633
PIN PULLER HYDRAULIC SYSTEM 635
PIN PULLER HYDRAULIC CIRCUIT 635
PIN PULLER HYDRAULIC SYSTEM 636
PIN PULLER HYDRAULIC CIRCUIT 636
HYDRAULIC TANK 637
BLADE LIFT AND RIPPER CONTROL VALVES 639
BLADE TILT CONTROL VALVE 640
SAFETY VALVE 641
SUCTION VALVE 642
MAIN RELIEF VALVE 642
ROTARY SERVO VALVE 643
SERVO VALVE HYDRAULIC SYSTEM 647
SERVO VALVE HYDRAULIC CIRCUIT 647
SERVO VALVE HYDRAULIC SYSTEM 648
SERVO VALVE HYDRAULIC CIRCUIT 648
CYLINDER 649
(1) BLADE LIFT 649
(2) BLADE TILT 651
QUICK DROP VALVE 652
RIPPER SELECTOR VALVE・PILOT CHECK VALVE 653
RIPPER CYLINDER 657
PIN PULLER VALVE 658
PIN PULLER CYLINDER 661
62 TESTING AND ADJUSTING 662
TESTING AND ADJUSTING 663
OIL PRESSURE MEASURING POINTS 664
OIL PRESSURE AND OIL TEMPERATURE MEASUREMENT TOOLS 664
OIL PRESSURE AND OIL TEMPERATURE MEASUREMENT AND ADJUSTMENT PROCEDURE 665
MEASUREMENT OF HYDRAULIC PUMP DELIVERY 666
MEASUREMENT OF OPERATING FORCE 668
MEASUREMENT OF HYDRAULIC DRIFT RATE OF WORK EQUIPMENT 669
STANDARD VALUE TABLE 670
63 DISASSEMBLY AND ASSEMBLY 674
DISASSEMBLY AND ASSEMBLY 675
DISMOUNTING OF HYDRAULIC PUMP 676
MOUNTING OF HYDRAULIC PUMP 678
DISMOUNTING OF BLADE TILT CONTROL VALVE 680
DISASSEMBLY OF BLADE TILT CONTROL VALVE 682
ASSEMBLY OF BLADE TILT CONTROL VALVE 683
MOUNTING OF BLADE TILT CONTROL VALVE 684
DISMOUNTING OF RIPPER AND BLADE CONTROL VALVE 686
DISASSEMBLY OF RIPPER AND BLADE CONTROL VALVE 689
ASSEMBLY OF RIPPER AND BLADE CONTROL VALVE 692
MOUNTING OF RIPPER AND BLADE CONTROL VALVE 695
DISMOUNTING OF RIPPER AND BLADE SERVO VALVE 698
MOUNTING OF RIPPER AND BLADE SERVO VALVE 700
DISMOUNTING OF BLADE TILT SERVO VALVE 702
MOUNTING OF BLADE TILT SERVO VALVE 703
DISMOUNTING OF PIN PULLER VALVE 704
MOUNTING OF PIN PULLER VALVE 706
DISMOUNTING OF RIPPER SELECTOR CONTROL VALVE 708
MOUNTING OF RIPPER SELECTOR CONTROL VALVE 709
DISMOUNTING OF RIPPER SELECTOR VALVE 710
DISASSEMBLY OF RIPPER SELECTOR VALVE 713
ASSEMBLY OF RIPPER SELECTOR VALVE 718
MOUNTING OF RIPPER SELECTOR VALVE 723
DISMOUNTING OF BLADE LIFT CYLINDER 726
DISASSEMBLY OF BLADE LIFT CYLINDER 727
ASSEMBLY OF BLADE LIFT CYLINDER 733
MOUNTING OF BLADE LIFT CYLINDER 739
DISMOUNTING OF BLADE TILT CYLINDER 740
DISASSEMBLY OF BLADE TILT CYLINDER 741
ASSEMBLY OF BLADE TILT CYLINDER 747
MOUNTING OF BLADE TILT CYLINDER 753
DISMOUNTING OF RIPPER LIFT CYLINDER 754
MOUNTING OF RIPPER LIFT CYLINDER 755
DISMOUNTING OF RIPPER TILT CYLINDER 756
MOUNTING OF RIPPER TILT CYLINDER 757
DISASSEMBLY OF RIPPER CYLINDER 758
ASSEMBLY OF RIPPER CYLINDER 764
DISMOUNTING OF PIN PULLER CYLINDER 770
MOUNTING OF PIN PULLER CYLINDER 771
64 MAINTENANCE STANDARD 772
MAINTENANCE STANDARD 773
HYDRAULIC CONTROL VALVE 774
(1) LIFT,TILT AND RIPPER VALVES 774
(2) MAIN RELIEF VALVE 775
(3) SUCTION VALVE AND SAFETY VALVE 776
(4) RIPPER SELECTOR VALVE 777
(5) PILOT VALVE 778
(6) RIPPER PIN PULLER VALVE 779
CYLINDER 780
(1) BLADE LIFT CYLINDER 780
(2) BLADE TILT CYLINDER 781
(3) RIPPER LIFT CYLINDER 782
(4) RIPPER TILT CYLINDER 783
(5) PIN PULLER CYLINDER 784
SERVO VALVE 785
(1) BLADE LIFT (WITH DETENT) 785
(2) BLADE TILT AND RIPPER (WITHOUT DETENT) 786
70 WORK EQUIPMENT 787
71 STRUCTURE AND FUNCTION 787
STRUCTURE AND FUNCTION 788
STRAIGHT TILT DOZER 789
VARIABLE MULTI RIPPER 791
VARIABLE GIANT RIPPER 792
CYLINDER STAY 793
72 TESTING AND ADJUSTING 794
TESTING AND ADJUSTING 795
STRAIGHT TILT DOZER AND U-DOZER INSTALLATION PROCEDURE 796
73 DISASSEMBLY AND ASSEMBLY 798
DISASSEMBLY AND ASSEMBLY 799
DISMOUNTING OF BLADE 800
DISASSEMBLY OF BLADE 802
ASSEMBLY OF BLADE 805
MOUNTING OF BLADE 808
DISASSEMBLY OF VARIABLE GIANT RIPPER 810
ASSEMBLY OF VARIABLE GIANT RIPPER 815
74 MAINTENANCE STANDARD 820
MAINTENANCE STANDARD 821
STRAIGHT TILT DOZER 822
(1) BLADE 822
(2) CUTTING EDGE AND END BIT 824
CYLINDER STAY 825
VARIABLE MULTI RIPPER 826
VARIABLE GIANT RIPPER 827
90 OTHERS 828
91 ELECTRICAL SYSTEM 828
ELECTRICAL SYSTEM 829
ELECTRICAL WIRING 830
WIRING DIAGRAM 831
WARNING MODULE 839
CORRECTIVE ACTIONS TO BE TAKEN WHEN WARNING MODULE IS ACTIVATED 840

DESCRIPTION:

Komatsu D355A-3 Bulldozer Shop Manual SEBM0195B09 – PDF DOWNLOAD 

FOREWORD:
This shop manual has been prepared as an aid in improving the quality of repairs Ьу giving the serviceman
ап accurate understanding of the product and Ьу showing him the correct way to perform and
make judgements. Make sure you understand the contents of this mar1ual and use it to full effect at every
availably opportunity.
Organization
This shop manual mainly contains the n,~cessary technical information for Operations performed in а service workshop. For ease of understanding, the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
Structure and function
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for trouЫeshooting.
Testing and adjusting
This section explains checks to Ье made before and after performing repairs, as well as adjustments to Ье made at completion of the checks and repairs. TrouЫeshooting charts correiating “Diagnoses” to “Causes” are also included in this section.
DisassemЫy and assemЫy
This section explains the order to Ье followed when removing, installing, disassemЫing or assemЫing each component, as well as precautions to Ье taken for these operations.
Maintemвnce standard
This section gives the judgement standards when inspecting disassemЫed parts.

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S.V 22/12/24