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Komatsu D355A-5 Crawler Bulldozer Shop Manual SEBM01950508 – PDF DOWNLOAD
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Komatsu D355A-5 Crawler Bulldozer Shop Manual SEBM01950508
MACHINE MODEL SERIAL NUMBER
D355A-5 12622 and up
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Description
Komatsu D355A-5 Crawler Bulldozer Shop Manual SEBM01950508
FILE DETAILS:
Komatsu D355A-5 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D355A-5
Serial Number: 12622 and up
Book Code: SEBM01950508
Issued: Printed in Japan 09-1995
Language: English
Pages: 723
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D355A-5 Crawler Bulldozer Shop Manual
FOREWORD:
This shop manual has men prepared as an aid in improving the quality of repairs by giving the servicemen 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 auailably opportunity.
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 trouble shooting.
Testing and adjusting :
This section explains checks to be made before and after performing repairs, 5 as well as adjustments to be made at completion of the checks and repairs. Trouble shooting charts correlating “Diagnoses” to “Causes” are also included in this section.
Disassembly and assembly :
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
Maintenance standards :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu D355A-5 Crawler Bulldozer Shop Manual
COVER............................................................................................................................................................................. 1 CONTENTS.......................................................................................................................................................................... 2 SAFETY............................................................................................................................................................................ 7 FOREWORD.......................................................................................................................................................................... 9 HOW TO READ THE SHOP MANUA;................................................................................................................................................... 10 HOISTING INSTRUCTIONS......................................................................................................................................................... 11 COATING MATERIALS............................................................................................................................................................. 12 STANDARD TIGHTENING TORQUE.................................................................................................................................................... 13 ELECTRIC WIRE CODE............................................................................................................................................................ 15 CONVERSION TABLE.............................................................................................................................................................. 16 TEMPERATURE................................................................................................................................................................... 21 WEIGHT TABLE.................................................................................................................................................................. 23 TABLE OF FUEL, COOLANT AND LUBRICANTS......................................................................................................................................... 25 10 STRUCTURE AND FUNCTION......................................................................................................................................................... 29 GENERAL....................................................................................................................................................................... 30 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM......................................................................................................................................... 32 TORQUE CONVERTER.............................................................................................................................................................. 34 TORQFLOW TRANSMISSION......................................................................................................................................................... 37 DISC CLUTCHES................................................................................................................................................................. 39 TRANSMISSION POWER TRAIN...................................................................................................................................................... 40 TORQFLOW HYDRAULIC PIPING..................................................................................................................................................... 46 TORQFLOW HYDRAULIC SYSTEM..................................................................................................................................................... 48 TORQFLOW HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................................ 49 TRANSMISSION CONTROL VALVE.................................................................................................................................................... 50 CONTROL VALVE SYSTEM DIAGRAM.................................................................................................................................................. 52 SAFETY VALVE.................................................................................................................................................................. 55 TRANSMISSION LUBRICATION RELIEF VALVE......................................................................................................................................... 56 TRANSMISSION PUMP............................................................................................................................................................. 57 TRANSMISSION AND STEERING OIL STRAINER........................................................................................................................................ 58 TRANSMISSION OIL FILTER....................................................................................................................................................... 59 BEVEL GEAR SHAFT AND STEERING CLUTCH.......................................................................................................................................... 60 STEERING AND BRAKE PIPING..................................................................................................................................................... 62 STEERING AND BRAKE HYDRAULIC SYSTEM........................................................................................................................................... 64 STEERING AND BRAKE HYDRAULIC CIRCUIT DIAGRAM.................................................................................................................................. 65 STEERING CONTROL VALVE........................................................................................................................................................ 66 STEERING MAIN RELIEF VALVE.................................................................................................................................................... 71 STEERING BRAKE AND BOOSTER.................................................................................................................................................... 72 STEERING PUMP................................................................................................................................................................. 76 STEERING OIL FILTER........................................................................................................................................................... 77 SPRING ASSIST BRAKE DEVICE.................................................................................................................................................... 78 PTO........................................................................................................................................................................... 82 FINAL DRIVE................................................................................................................................................................... 84 TRACK FRAME................................................................................................................................................................... 86 RECOIL SPRING................................................................................................................................................................. 87 IDLER......................................................................................................................................................................... 88 TRACK ROLLER AND CARRIER ROLLER............................................................................................................................................... 89 TRACK (Lubricated track link)................................................................................................................................................. 90 TRACK (Dry type track link)................................................................................................................................................... 91 SUSPENTION.................................................................................................................................................................... 92 HYDRAULIC PIPING.............................................................................................................................................................. 94 HYDRAULIC CIRCUIT DIAGRAM..................................................................................................................................................... 99 HYDRAULIC TANK................................................................................................................................................................100 HYDRAULIC PUMP................................................................................................................................................................101 HYDRAULIC CONTROL VALVE.......................................................................................................................................................102 HYDRAULIC CYLINDER............................................................................................................................................................106 RIPPER SELECTOR VALVE AND PILOT CHECK VALVE...................................................................................................................................110 PILOT VALVE...................................................................................................................................................................114 SERVO VALVE HYDRAULIC SYSTEM..................................................................................................................................................115 ROTARY SERVO VALVE............................................................................................................................................................116 PIN PULLER HYDRAULIC SYSTEM AND DIAGRAM (for giant ripper)....................................................................................................................120 PIN PULLER VALVE (for giant ripper)...........................................................................................................................................121 PIN PULLER CYLINDER (for giant ripper)........................................................................................................................................124 STRAIGHT TILT DOZER...........................................................................................................................................................126 VARIABLE MULTIPLE SHANK RIPPER................................................................................................................................................128 VARIABLE GIANT RIPPER.........................................................................................................................................................129 CYLINDER STAY.................................................................................................................................................................130 EVMS (electronic vehicle monitoring system0...................................................................................................................................131 AIR CONDITIONER...............................................................................................................................................................138 20 TESTING AND ADJUSTING..........................................................................................................................................................142 TABLE OF STANDARD VALUES FOR ENGINE...........................................................................................................................................143 TABLE OF STANDARD VALUES FOR CHASSIS..........................................................................................................................................144 TABLE OF ELECTRICAL JUDGEMENT STANDARD VALVE..................................................................................................................................150 TESTING AND ADJUSTING TOOL LIST...............................................................................................................................................151 ADJUSTING VALUE CLEARANCE.....................................................................................................................................................152 MEASURING COMPRESSION PRESSURE................................................................................................................................................153 ADJUSTING FUEL INJECTION TIMING...............................................................................................................................................154 MEASURING TORQUE CONVERTER STALL SPEED........................................................................................................................................155 MEASURING HYDRAULIC PRESSURE..................................................................................................................................................156 BLEEDING AIR FROM HYDRAULIC CYLINDER..........................................................................................................................................158 ADJUSTING LINKAGE.............................................................................................................................................................159 ADJUSTING GEAR SHIFT LEVER LINKAGE........................................................................................................................................161 ADJUSTING STEERING CONTROL LINKAGE........................................................................................................................................163 ADJUSTING TRAVEL OF BRAKE LINKAGE.........................................................................................................................................164 ADJUSTING BRAKE PEDAL LINKAGE.............................................................................................................................................165 ADJUSTING SPRING ASSIST BRAKE.............................................................................................................................................166 ADJUSTING BLADE CONTROL LINKAGE...........................................................................................................................................167 ADJUSTING RIPPER CONTROL LINKAGE..........................................................................................................................................168 TROUBLESHOOTING...............................................................................................................................................................170 SEQUENCE OF EVENTS IN TROUBLESHOOTING.....................................................................................................................................171 CHECKS BEFORE TROUBLESHOOTING.............................................................................................................................................172 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................................................................................173 PREVENTING RECURRENCE OF THE SAME TROUBLE.................................................................................................................................174 PRECAUTIONS WHEN CARRYING OUT MAINTENANCE.................................................................................................................................175 HANDLING CONNECTORS.......................................................................................................................................................182 METHOD OF READING TROUBLESHOOTING TABLE...................................................................................................................................183 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................................................................185 LOCATION OF CONNECTORS FOR TROUBLESHOOTING................................................................................................................................189 CONNECTION TABLE FOR CONNECTOR PIN........................................................................................................................................190 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM........................................................................................................................198 H-1 Torque converter oil temperature too high.........................................................................................................................199 H-2 Machine does not move off.........................................................................................................................................201 H-3 Machine lacks power or speed......................................................................................................................................203 H-4 Machine moves when engine is started..............................................................................................................................204 H-5 Excessive time lag when starting machine or shifting gear.........................................................................................................204 H-6 Excessive shock when starting machine or shifting gear............................................................................................................205 H-7 Machine travels in one direction only (FORWARD OR REVERSE)........................................................................................................205 H-8 Steering clutch does not disengage................................................................................................................................206 H-9 Steering clutch slips.............................................................................................................................................207 H-10 Steering brake does not work.....................................................................................................................................208 H-11 Blade lift lacks power and speed.................................................................................................................................209 H-12 Blade does not lift..............................................................................................................................................210 H-13 The front of machine cannot be raised off ground by the blade....................................................................................................211 H-14 Hydraulic drift of lift cylinder is large........................................................................................................................212 H-15 Blade moves unsteadily when leveling the ground..................................................................................................................213 H-16 Blade lowers under the following conditions......................................................................................................................213 H-17 Travel of the piston rods in the right and left lift cylinders is diffferent.....................................................................................213 H-18 Blade tilting force is lack, blade tilting speed is slow, the machine cannot be raised off the ground by blade tilting force.....................................214 H-19 Tilt cylinder does not move off. (Tilting is impossible).........................................................................................................215 H-20 Hydraulic drift of tilt cylinder is large........................................................................................................................216 H-21 Hydraulic drift of ripper cylinder is large......................................................................................................................217 H-22 Control lever operating force is heavy...........................................................................................................................218 TROUBLESHOOTING OF ELECTRICAL SYSTEM......................................................................................................................................220 TABLE OF FAILURE MODES AND CAUSES....................................................................................................................................221 E-1 Even when preheating switch is turned on, APS pilot lamp on monitor panel does not light up.......................................................................223 Related electrical circuit diagram................................................................................................................................225 E-2 When preheating switch is turned on, APX pilot lamp on monitor panel light up, but it doesn't go out, or the time taken for it to go out is not 60 - 100 sec.....227 E-2 Related electrical circuit diagram............................................................................................................................228 E-3 Even when engine is granked, it does not start....................................................................................................................229 Related electrical circuit diagram................................................................................................................................231 E-4 APS control unit does not work properly...........................................................................................................................233 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM.................................................................................................................................236 TABLE OF FAILURE MODES AND CAUSES.....................................................................................................................................237 M-1 No Monitor panel display is given when starting switch is turned ON...............................................................................................238 M-2 When starting switch is turned ON, alllamps on monitor panel stay lighted and do not go out.......................................................................238 M-3 When starting switch is ON (Engine stopped), check items flash....................................................................................................239 M-4 No preheating is being carried out, but preheating display lights up..............................................................................................240 M-5 When starting switch is turned ON and engine is started, check items flash........................................................................................241 M-6 When starting switch is turned ON (Engine stopped), caution items flash...........................................................................................242 M-7 When starting switch is turned ON (Engine started), caution items flash...........................................................................................243 M-8 When starting switch is turned ON (Engine stopped), buzzer does not sound for one second..........................................................................245 M-9 When starting switch is turned ON (Engine stopped), caution lamp does not light up for 2 seconds..................................................................246 M-10 Panel lighting of monitor panel does not light up. (Liquid crystal display is normal)............................................................................247 M-11 Service meter does not move after engine is started..............................................................................................................248 M-12 Engine coolant temperature gauge shows abnormally low temperature................................................................................................249 M-13 Engine coolant temperature gauge gives no display................................................................................................................249 M-14 Torque converter oil temperature gauge shows abnormally low temperature..........................................................................................250 M-15 Torque converter oil temperature gauge gives no display..........................................................................................................250 M-16 Fuel gauge always displays tank full.............................................................................................................................251 M-17 Fuel gauge gives no display......................................................................................................................................251 20 TROUBLESHOOTING................................................................................................................................................................252 Preparation for Troubleshooting...............................................................................................................................................252 Position of connectors........................................................................................................................................................253 30 DISASSEMBLY AND ASSEMBLY.......................................................................................................................................................259 Method of Using Manual........................................................................................................................................................263 Precautions when carrying out operation.......................................................................................................................................265 Dismounting / Mounting of Starter Motor.......................................................................................................................................268 Removing / Installing of Fan Belt.............................................................................................................................................269 Dismounting / Mounting of Alternator..........................................................................................................................................270 Dismounting / Mounting of engine Oil Cooler...................................................................................................................................272 Dismounting / Mounting of Fuel Injection......................................................................................................................................276 Dismounting / Mounting of Water Pump..........................................................................................................................................280 Dismounting / Mounting of Turbo Charger.......................................................................................................................................284 Dismounting / Mounting of After Cooler........................................................................................................................................288 Dismounting / Mounting of Nozzle Holder.......................................................................................................................................294 Dismounting / Mounting of Cylinder Head.......................................................................................................................................296 Dismounting / Mounting of Radiator............................................................................................................................................308 Dismounting / Mounting of Fuel Tank...........................................................................................................................................312 Dismounting / Mounting of PTO.................................................................................................................................................314 Dismounting / Mounting of Torque Converter Oil Cooler.........................................................................................................................318 Dismounting / Mounting of Engine..............................................................................................................................................324 Dismounting / Mounting of Chassis-Related Parts from Engine...................................................................................................................336 Dismounting / Mounting of Torque Converter....................................................................................................................................340 Disassembly / Assembly of Torque Converter....................................................................................................................................344 Dismounting / Mounting of Torque Converter Relief Valve.......................................................................................................................358 Dismounting / Mounting of Torque Converter Regulator Valve....................................................................................................................359 Dismounting / Mounting of Torqflow Transmission...............................................................................................................................360 Disassembly / Assembly of Torqflow Transmission...............................................................................................................................370 Disassembly of No. 1,3 Carriers and No. 1,2 Sun gears and bearing cage........................................................................................................379 Disassembly of No. 4 Housing and No. 5,6 Gears and PTO Shaft..................................................................................................................382 Assembly of Torqflow Transmission.............................................................................................................................................386 Assembly of No. 4 Housing and No. 5,6 Gears and PTO Shaft.....................................................................................................................386 Assembly of No. 1,2 Sun Gears and Bearing Cage................................................................................................................................390 Dismounting / Mounting of Torqflow Transmission Lubrication Valve.............................................................................................................404 Dismounting / Mounting of Transmission Control Valve..........................................................................................................................405 Dissambly / Assembly of Transmission Control Valve............................................................................................................................406 Dismounting / Mounting of Steering Clutch.....................................................................................................................................414 Disassembly / Assembly of Steering Clutch.....................................................................................................................................420 Dismounting / Mounting of Bevel Gear Shaft and Bevel Gear.....................................................................................................................424 Dismounting / Mounting of Steering / Brake Interlocking Valve.................................................................................................................432 Disassembly / Assembly of Steering / Brake Interlocking Valve.................................................................................................................434 Disassembly / Assembly of Steering Bake Booster...............................................................................................................................436 Dismounting/ Mounting of Steering Main Relief Valve...........................................................................................................................440 Disassembly / Assembly of Steering Main Relief Vallve.........................................................................................................................440 Dismounting / Mounting of Brake Assister Cylinder Ass'y.......................................................................................................................441 Disassembly / Assmebly of Brake Assister Cylinder Ass'y.......................................................................................................................442 Dismounting / Mounting of Final Drive 1st Pinion..............................................................................................................................448 Disassembly / Assembly of Final Drive.........................................................................................................................................454 Dismounting / Mounting of Transmission Pump..................................................................................................................................470 Dismounting / Mounting of Steering Pump.......................................................................................................................................471 Checking before removal of Track Shoe Assembly................................................................................................................................472 Removal of Track Shoe Assembly (Normal).......................................................................................................................................473 Removal of Track Shoe Assembly (When there is abnormality inside track frame).................................................................................................474 Installation of Track Shoe Assembly...........................................................................................................................................475 Truck Line Disassembly and Assembly...........................................................................................................................................476 Overall Disassembly / Assembly of Track Shoe..................................................................................................................................480 Press-Fitting Jig Dimension Table for Link Press..............................................................................................................................500 Field Disassembly / Assembly of One link......................................................................................................................................501 Disassembly / Assembly of Master Link.........................................................................................................................................505 Dismounting / Mounting of Carrier Roller......................................................................................................................................510 Dismounting / Mounting of Track Roller........................................................................................................................................512 Dismounting / Mounting of Idler...............................................................................................................................................516 Removal / Installation of Recoil Spring.......................................................................................................................................520 Disassembly / Assembly of Recoil Spring.......................................................................................................................................524 Dismounting / Mounting of Track Frame.........................................................................................................................................530 Dismounting / Mounting of Ripper and Blade Control Valve......................................................................................................................534 Disassembly / Assembly of Ripper and Blade Control Valve......................................................................................................................540 Dismounting / Mounting of Blade Tilt Control Valve............................................................................................................................546 Disassembly / Assembly of Blade Tilt Control Valve............................................................................................................................550 Dismounting / Mounting of Hydraulic Pump......................................................................................................................................551 Dismounting / Mounting of Ripper and Blade Servo Valve........................................................................................................................552 Dismounting / Mounting of Blade Tilt Servo Valve..............................................................................................................................556 Dismounting / Mounting of Pin Puller Valve....................................................................................................................................558 Dismounting / Mounting of Ripper Selector Control Valve.......................................................................................................................562 Dismounting / Mounting Ripper Selector Valve..................................................................................................................................564 Disassembly / Assembly of Ripper Selector Valve...............................................................................................................................570 Dismounting / Mounting of Blade Lift Cylinder.................................................................................................................................578 Disassembly / Assembly of Blade Lift Cylinder.................................................................................................................................580 Dismounting / Mountain of Blade Tilt Cylinder.................................................................................................................................590 Disassembly / Assembly of Blade Tilt Cylinder.................................................................................................................................592 Dismounting / Mounting of Ripper Lift Cylinder................................................................................................................................602 Dismounting / Mounting of Ripper Tilt Cylinder................................................................................................................................604 Disassembly / Assembly of Ripper Cylinder.....................................................................................................................................606 Dismounting / Mounting of Pin Puller Cylinder.................................................................................................................................616 Dismounting / Mounting of Blade...............................................................................................................................................618 Disassembly / Assembly of Blade...............................................................................................................................................622 Disassembly / Assembly of Variable Giant Ripper...............................................................................................................................628 Dismounting / Mounting of Floor Frame.........................................................................................................................................636 Dismounting / Mounting of Rops Cab............................................................................................................................................642 Tilting / Returning of Rops Cab...............................................................................................................................................648 40 MAINTENANCE STANDARD...........................................................................................................................................................656 Transmission Pump.............................................................................................................................................................657 Steering Pump.................................................................................................................................................................658 Torque Converter..............................................................................................................................................................659 Transmission Lubrication Relief Valve.........................................................................................................................................662 Torqflow Transmission.........................................................................................................................................................663 Transmission Control Valve....................................................................................................................................................665 Bevel Gear Shaft..............................................................................................................................................................667 Steering Clutch...............................................................................................................................................................669 Steering Control Valve........................................................................................................................................................671 Steering Main Relief Valve....................................................................................................................................................673 Brake Assister Turomatic Drain Valve..........................................................................................................................................674 Brake Assister Check Valve....................................................................................................................................................675 Spring Assist Brake Cylinder..................................................................................................................................................676 Spring Assist Brake Auto Drain Valve..........................................................................................................................................677 Steering Brake and Booster....................................................................................................................................................679 Final Drive...................................................................................................................................................................681 Track Frame...................................................................................................................................................................685 Recoil Spring.................................................................................................................................................................686 Idler.........................................................................................................................................................................687 Track Roller..................................................................................................................................................................689 Carrier Roller................................................................................................................................................................691 Track Shoe (Lubricated track link)............................................................................................................................................693 Track (Dry type track link)...................................................................................................................................................695 Hydraulic Pump................................................................................................................................................................697 Hydraulic Control Valve.......................................................................................................................................................698 Quike Drop Valve..............................................................................................................................................................701 Ripper Selector Valve and Pilot check Valve...................................................................................................................................702 Ripper Pilot Valve............................................................................................................................................................703 Ripper Pin Puller Valve (for Giant Ripper)....................................................................................................................................704 Hydraulic Cylinder............................................................................................................................................................705 Pin Puller Cylinder (for Giant Ripper)........................................................................................................................................707 Servo Valve...................................................................................................................................................................708 Straight Tilt Dozer...........................................................................................................................................................709 Cylinder Stay.................................................................................................................................................................710 Variable Multiple Shank Ripper................................................................................................................................................711 Variable Giant Ripper.........................................................................................................................................................713 90 DRAWINGS.......................................................................................................................................................................716 ELECTRICAL CIRCUIT DIAGRAM....................................................................................................................................................719 Chassis Electrical Circuit................................................................................................................................................719 Cab Electrical Circuit....................................................................................................................................................720 Related Electrical Circuit................................................................................................................................................721 APS System............................................................................................................................................................721 Monitor System........................................................................................................................................................722 LOCATION OF CONNECTORS........................................................................................................................................................723
KOMATSU D355A-5 CRAWLER BULLDOZER SHOP MANUAL SEBM01950508 – PDF DOWNLOAD:
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- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
