Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
Komatsu D375A-3 17001 and up Crawler Bulldozer Shop Manual – PDF DOWNLOAD
Original price was: $53.95.$34.95Current price is: $34.95.
Komatsu D375A-3 17001 and up Crawler Bulldozer Shop Manual
Book Code: SEBM008403
MACHINE MODEL SERIAL NUMBER
D375A-3 17001 and up
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
Komatsu D375A-3 17001 and up Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D375A-3 17001 and up Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D375A-3
Serial Number: 17001 and up
Book Code: SEBM008403
Language: English
Pages: 869
File Format: Portable Document Format (PDF)
KOMATSU D375A-3 17001 AND UP CRAWLER BULLDOZER SHOP MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Komatsu D375A-3 17001 and up Crawler Bulldozer Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve 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 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.
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 troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in thissection.
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 STANDARD :
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu D375A-3 17001 and up Crawler Bulldozer Shop Manual
COVER..................................................................................................................................................... 1 CONTENTS.................................................................................................................................................. 2 01 GENERAL................................................................................................................................................ 26 SPECIFICATION DRAWING................................................................................................................................. 27 SPECIFICATIONS........................................................................................................................................ 29 WEIGHT TABLE.......................................................................................................................................... 34 TABLE OF FUEL ,COOLANT AND LUBRICANTS................................................................................................................. 36 10 STRUCTURE AND FUNCTION................................................................................................................................. 37 ENGINE CONTROL........................................................................................................................................ 38 POWER TRAIN........................................................................................................................................... 39 OVERALL DRAWING OF POWER TRAIN UNIT................................................................................................................... 41 POWER TRAIN HYDRAULIC PIPING DIAGRAM.................................................................................................................. 43 POWER TRAIN HYDRAULIC SYSTEM DRAWING.................................................................................................................. 44 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................................. 45 DAMPER,UNIVERSAL JOINT................................................................................................................................ 46 TORQUE CONVERTER,PTO.................................................................................................................................. 48 TORQUE CONVERTER VALVE................................................................................................................................ 53 TRANSMISSION CONTROL.................................................................................................................................. 62 TRANSMISSION.......................................................................................................................................... 63 TRANSMISSION CONTROL VALVE............................................................................................................................ 69 LUBRICATION RELIEF VALVE.............................................................................................................................. 76 SCAVENGING PUMP STRAINER.............................................................................................................................. 77 POWER TRAIN PUMP STRAINER............................................................................................................................. 78 POWER TRAIN,LUBRICATION OIL FILTER.................................................................................................................... 79 STEERING,BRAKE CONTROL................................................................................................................................ 80 TRANSFER,BEVEL GEAR SHAFT,STEERING.................................................................................................................... 82 STEERING CONTROL VALVE................................................................................................................................ 86 FINAL DRIVE........................................................................................................................................... 94 TRACK FRAME........................................................................................................................................... 97 RECOIL SPRING......................................................................................................................................... 99 TRACK ROLLER BOGIE....................................................................................................................................100 MAIN FRAME............................................................................................................................................101 SUSPENSION............................................................................................................................................102 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM...............................................................................................................104 PPC CONTROL PIPING DIAGRAM............................................................................................................................108 WORK EQUIPMENT CONTROL................................................................................................................................109 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (TILTDOZER)...................................................................................................110 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..............................................................................................................111 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (DUAL TILTDOZER)..............................................................................................112 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..............................................................................................................113 HYDRAULIC TANK........................................................................................................................................114 PPC CHARGE VALVE......................................................................................................................................115 ACCUMULATOR...........................................................................................................................................117 PPC LOCK VALVE........................................................................................................................................118 PPC VALVE.............................................................................................................................................119 PISTON VALVE..........................................................................................................................................129 QUICK DROP VALVE......................................................................................................................................130 PIN PULLER SWITCH.....................................................................................................................................131 PIN PULLER SOLENOID VALVE.............................................................................................................................132 BLADE CONTROL KNOB....................................................................................................................................134 PITCH,DUAL TILT SOLENOID VALVE........................................................................................................................135 MAIN CONTROL VALVE....................................................................................................................................137 CYLINDER STAY.........................................................................................................................................163 BLADE ...............................................................................................................................................164 RIPPER................................................................................................................................................166 CAB MOUNT.............................................................................................................................................168 CAB .................................................................................................................................................169 AIR CONDITIONER.......................................................................................................................................171 ACTUAL ELECTRIC WIRING DIAGRAM........................................................................................................................172 ELECTRIC CIRCUIT DIAGRAM..............................................................................................................................174 MACHINE MONITOR SYSTEM................................................................................................................................177 MODE SELECTION SYSTEM.................................................................................................................................185 ENGINE CONTROL SYSTEM.................................................................................................................................194 SWITCH PANEL..........................................................................................................................................202 ENGINE START SAFETY SYSTEM............................................................................................................................204 APS...................................................................................................................................................205 TORQUE CONVERTER LOCK-UP CONTROL SYSTEM...............................................................................................................207 20 TESTING AND ADJUSTING..................................................................................................................................210 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.........................................................................................................211 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS........................................................................................................212 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS.....................................................................................................217 STANDARD VALUE TABLE FOR MACHINE MONITOR..............................................................................................................224 TABLE OF TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING..............................................................................................227 TABLE OF APPLICABLE T-ADAPTER KITS (TOOL M)...........................................................................................................228 MEASURING ENGINE SPEED................................................................................................................................230 MEASURING EXHAUST COLOR...............................................................................................................................231 ADJUSTING VALVE CLEARANCE.............................................................................................................................232 MEASURING COMPRESSION PRESSURE........................................................................................................................233 MEASURING BLOW-BY PRESSURE............................................................................................................................234 MEASURING ENGINE OIL PRESSURE.........................................................................................................................235 TESTING AND ADJUSTING FUEL INJECTION TIMING ..........................................................................................................236 TESTING AND ADJUSTING ALTERNATOR BELT TENSION.........................................................................................................238 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR.....................................................................................238 MEASURING EXHAUST TEMPERATURE.........................................................................................................................239 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)........................................................................................................240 MEASURING TORQUE CONVERTER STALL SPEED................................................................................................................241 MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL)........................................................................242 ADJUSTING FUEL CONTROL LINKAGE........................................................................................................................243 ADJUSTING DECELERATOR PEDAL...........................................................................................................................247 ADJUSTING JOYSTICK (STEERING,DIRECTIONAL,SPEED CONTROL LEVER),PARKING BRAKE LEVER LINKAGE.............................................................248 ADJUSTING BRAKE PEDAL LINKAGE.........................................................................................................................252 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE..............................................................................................................253 MEASURING POWER TRAIN OIL PRESSURE....................................................................................................................254 MEASURING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE.............................................................................................257 TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE.........................................................................................259 MEASURING PPC VALVE OUTPUT PRESSURE...................................................................................................................260 ADJUSTING PPC VALVE...................................................................................................................................261 MEASURING ON-OFF SOLENOID VALVE OUTPUT PRESSURE.......................................................................................................262 BLEEDING AIR FROM HYDRAULIC CYLINDERS.................................................................................................................263 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT.....................................................................................................263 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER.....................................................................................264 MEASURING LEAKAGE INSIDE CYLINDER.....................................................................................................................265 ADJUSTING SEMI U-TILTDOZER............................................................................................................................266 ADJUSTING CLEARANCE OF IDLER..........................................................................................................................268 SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE........................................................................................................269 TROUBLESHOOTING.......................................................................................................................................270 POINTS TO REMEMBER WHEN TROUBLESHOOTING ..........................................................................................................271 SEQUENCE OF EVENTS IN TROUBLESHOOTING.............................................................................................................272 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..................................................................................................273 CHECKS BEFORE TROUBLESHOOTING.....................................................................................................................281 TYPE OF CONNECTOR AND POSITION OF INSTALLATION....................................................................................................282 CONNECTOR ARRANGEMENT DIAGRAM.....................................................................................................................284 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS........................................................................................................286 MODE SELECTION SYSTEM.............................................................................................................................296 METHOD OF USING JUDGEMENT TABLE...................................................................................................................298 METHOD OF USING TROUBLESHOOTING CHARTS............................................................................................................299 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE).........................................................................................................301 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................................................302 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).................................................................................306 S-2 ENGINE DOES NOT START.....................................................................................................................307 1) ENGINE DOES NOT TURN...................................................................................................................307 2) ENGINE TURNS BUT TO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)...............................................................308 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED).............................................................309 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)......................................................................................310 S-4 ENGINE STOPS DURING OPERATIONS............................................................................................................311 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).................................................................................................312 S-6 ENGINE LACKS OUTPUT (NO POWER)............................................................................................................313 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................................................314 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE).....................................................................................315 S-9 OIL BECOMES CONTAMINATED QUICKLY..........................................................................................................316 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................................................317 S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN....................................................................318 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)...............................................................................319 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)......................................................................................................320 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING).........................................................................................321 S-15 ABNORMAL NOISE IS MADE...................................................................................................................322 S-16 VIBRATION IS EXCESSIVE...................................................................................................................323 TROUBLESHOOTING OF ELECTRICAL SYSTEM (MODE SELECTION ELECTRONIC SYSTEM) (E-S MODE)................................................................324 TABLE OF FAILURE MODES AND CAUSES (MODE SELECTION SYSTEM).....................................................................................325 ELECTRICAL CIRCUIT DIAGRAM FOR MODE SELECTION SYSTEM..........................................................................................327 1.ELECTRICAL CIRCUIT DIAGRAM FOR MODE SELECTION,SHOE SLIP CONTROLLER SYSTEM...............................................................327 2.ELECTRICAL CIRCUIT DIAGRAM FOR TORQUE CONVERTER LOCK-UP SYSTEM..........................................................................329 E-S1 TORQUE CONVERTER LOCK-UP DOES NOT WORK (LOCK-UP DISPLAY LAMP DOES NOT LIGHT UP)..........................................................330 E-S2 TORQUE CONVERTER LOCK-UP REMAINS ENGAGED (LOCK-UP DISPLAY LAMP DOES NOT GO OUT)..........................................................333 a) LOCK-UP DISPLAY LAMP DOES NOT GO OUT...................................................................................................333 b) LOCK-UP DISPLAY LAMP LIGHTS UP BUT LOCK-UP IS NOT ACTUATED.............................................................................333 E-S3 MODE DOES NOT SWITCH WHEN ECONOMY MODE SWITCH IS TURNED ON (MONITOR PANEL LED IS NORMAL).................................................334 E-S4 REVERSE SLOW IS NOT ACTUATED WHEN REVERSE SLOW SWITCH IS TURNED ON (MONITOR PANEL LED IS NORMAL).........................................337 E-S5 SHOE SLIP CONTROLLER IS NOT ACTUATED WHEN SHOE SLIP CONTROLLER SWITCH IS TURNED ON (MONITOR PANEL LED IS NORMAL).........................338 E-S6 SELECTED LEVEL DOES NOT CHANGE WHEN ROCKBED SELECTION SWITCH IS PRESSED (MONITOR PANEL LED IS NORMAL)....................................341 E-S7 ENGINE CANNOT BE CONTROLLED,ENGINE STALLS,ENGINE CANNOT BE STARTED (WHEN SHOE SLIP CONTROLLER IS ON).....................................344 E-S8 SHOE SLIP IS NOT DETECTED WHEN SHOE SLIP CONTROLLER IS ON................................................................................345 E-S9 STARTING MODULATION DOES NOT WORK WHEN SHOE SLIP COMPTROLLER IS ON.......................................................................346 E-S10 THERE IS NO UP/DOWN OF DRAWBAR PULL BY USING RIPPER LEVER WHEN SHOE SLIP CONTROLLER IS ON...............................................346 E-S11 ABNORMALITY IN RIPPER UP,DOWN,TILT SIGNAL,REVERSE SIGNAL................................................................................348 TROUBLESHOOTING OF SHOE SLIP CONTROLLER,ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM(G MODE)........................................................351 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE....................................................................352 ELECTRICAL CIRCUIT DIAGRAM OF G MODE..........................................................................................................358 G-1 [ABNORMALITY IN ENGINE] IS DISPLAYED......................................................................................................361 G-2 [ABNORMALITY IN ACCELERATION SENSOR POWER SOURCE] IS DISPLAYED............................................................................362 G-3 [ABNORMALITY IN TORQUE CONVERTER SPEED SENSOR] IS DISPLAYED...............................................................................363 G-4 [ABNORMALITY IN ENGINE SPEED SENSOR] IS DISPLAYED.........................................................................................364 G-5 [ABNORMALITY IN ECONOMY MODE SELECTION] IS DISPLAYED......................................................................................365 G-6 [ABNORMALITY IN CONTROL MODE] IS DISPLAYED................................................................................................366 G-7 [ABNORMALITY IN ACCELERATION SENSOR] IS DISPLAYED.........................................................................................367 G-8 [ABNORMALITY IN RIPPING MODE SELECTION] IS DISPLAYED......................................................................................368 G-9 [ABNORMALITY IN MANUAL POTENTIOMETER] IS DISPLAYED........................................................................................369 G-10 [SHORT CIRCUIT IN GOVERNOR MOTOR SYSTEM] IS DISPLAYED....................................................................................370 G-11 [DISCONNECTION IN GOVERNOR MOTOR SYSTEM] IS DISPLAYED....................................................................................371 G-12 [ABNORMALITY IN FEEDBACK POTENTIOMETER] IS DISPLAYED.....................................................................................372 G-13 [ABNORMALITY IN SHOE SLIP CONTROL COMMAND] IS DISPLAYED..................................................................................374 G-14 [ABNORMALITY IN SHOE SLIP CONTROLLER] IS DISPLAYED.......................................................................................375 G-15 [ABNORMALITY IN POWER SOURCE] IS DISPLAYED...............................................................................................376 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE)......................................................................................377 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS)..........................................................................378 H-1 MACHINE LACKS POWER (LACKS DRAWBAR PULL)..................................................................................................380 H-2 MACHINE DOES NOT MOVE (2ND,3RD,ENGINE RUNNING)............................................................................................382 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE..................................................................................................384 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE) ............................................................................386 H-5 TIME LAG IS EXCESSIVE WHEN SHIFTING GEAR OR CHANGING DIRECTION............................................................................387 H-6 MACHINE DOES NOT TURN (CAN TRAVEL IN STRAIGHT LINE).......................................................................................388 H-7 MACHINE TURNS ONLY IN ONE DIRECTION (LEFT OR RIGHT) [JOYSTICK (STEERING,DIRECTIONAL,SPEED LEVER) OPERATED]................................389 H-8 MACHINE TURNS TOO FAR.....................................................................................................................390 H-9 BRAKES DO NOT WORK........................................................................................................................391 H-10 TORQUE CONVERTER LOCK-UP DOES NOT WORK...................................................................................................391 H-11 POWER TRAIN OIL OVERHEATS................................................................................................................392 H-101 ALL WORK EQUIPMENT SPEEDS ARE SLOW......................................................................................................394 H-102 WORK EQUIPMENT DOES NOT MOVE............................................................................................................396 H-103 BLADE LIFT SPEED IS SHOW OR LACKS POWER.................................................................................................397 H-104 BLADE TILT SPEED IS SLOW OR LACKS POWER.................................................................................................397 H-105 RIPPER LIFT SPEED IS SLOW OR LACKS POWER................................................................................................398 H-106 RIPPER TILT SPEED IS SLOW OR LACKS POWER................................................................................................398 H-107 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT.................................................................................................399 H-108 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT.................................................................................................399 H-109 EXCESSIVE HYDRAULIC DRIFT OF RIPPER.....................................................................................................400 H-110 PIN-PULLER CYLINDER DOES NOT WORK.......................................................................................................400 H-111 BLADE PITCH DOES NOT WORK...............................................................................................................401 H-112 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP...............................................................................................401 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)................................................................................................402 TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)....................................................................................403 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR M MODE,E MODE..........................................................................................405 M-1 WHEN STARTING SWITCH IS TURNED ON,NO DISPLAY IS GIVEN ON MONITOR PANEL....................................................................407 M-2 WHEN STARTING SWITCH IS TURNED ON,MONITOR PANEL LAMPS ALL LIGHT UP BUT DO NOT GO OUT......................................................407 M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED),CHECK ITEMS FLASH......................................................................408 a) (RADIATOR WATER LEVEL) FLASHES.........................................................................................................408 b) (ENGINE OIL LEVEL) FLASHES.............................................................................................................408 M-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED),CAUTION ITEMS FLASH (BATTERY CHARGE,ENGINE OIL PRESSURE DO NOT LIGHT UP)...............409 a) ALTERNATOR SYSTEM......................................................................................................................409 b) ENGINE OIL PRESSURE SENSOR SYSTEM......................................................................................................410 M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED,CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR IN ENGINE)....411 a) (BATTERY CHARGE) FLASHES...............................................................................................................411 b) (ENGINE OIL PRESSURE) FLASHES..........................................................................................................411 c) (RADIATOR WATER LEVEL) FLASHES.........................................................................................................412 d) COOLANT TEMPERATURE) FLASHES...........................................................................................................412 e) (POWER TRAIN OIL TEMPERATURE) FLASHES..................................................................................................413 f) (HYDRAULIC OIL TEMPERATURE) FLASHES....................................................................................................413 M-6 ABNORMALITY IN (PREHEATING)...............................................................................................................414 M-7 ABNORMALITY IN BUZZER.....................................................................................................................415 a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND.........................................................................................415 b) MONITOR DISPLAY IS NORMAL BUT BUZZER SOUNDS............................................................................................415 M-8 ABNORMALITY IN WARNING LAMP...............................................................................................................416 a) CAUTION ITEM FLASHES BUT WARNING LAMP DOES NOT FLASH...................................................................................416 b) MONITOR DISPLAY IS NORMAL BUT WARNING LAMP LIGHTS UP...................................................................................416 M-9 ABNORMALITY IN GAUGE......................................................................................................................417 a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE........................................................................................417 b) ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE....................................................................417 c) ABNORMALITY IN FUEL LEVEL GAUGE........................................................................................................418 M-10 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED......................................................................................419 M-11 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMP,WORKING LAMP ARE NORMAL)............................................................420 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....................................................................................................421 ELECTRICAL CIRCUIT DIAGRAM FOR STARTING AND APS SYSTEM........................................................................................422 ELECTRICAL CIRCUIT DIAGRAM FOR INSIDE OPERATOR'S CAB..........................................................................................423 E-1 ENGINE DOES NOT START.....................................................................................................................424 E-2 DEFECTIVE OPERATION OF APS................................................................................................................426 a) PREHEATING MONITOR LAMP DOES NOT LIGHT UP DURING PREHEATING............................................................................426 b) PREHEATING MONITOR LAMP STAYS LIGHTED UP AFTER PREHEATING IS COMPLETED.................................................................426 c) PREHEATING MONITOR LAMP FLASHES AFTER PREHEATING IS COMPLETED..........................................................................427 d) PREHEATING MONITOR LAMP LIGHTS UP WHEN ENGINE IS STARTED (STARTING SWITCH AT START) AFTER PREHEATING IS COMPLETED......................427 e) APS IS NOT ACTUATED WHEN WATER TEMPERATURE IS BELOW 20℃................................................................................428 f) APS IS ACTUATED WHEN WATER TEMPERATURE IS ABOVE 20℃....................................................................................430 g) APS IS ACTUATED WHEN WATER TEMPERATURE IS BELOW 20℃ BUT APS SWITCH IS NOT TURNED ON....................................................430 E-3 DEFECTIVE OPERATION OF BACK-UP ALARM......................................................................................................431 a) BACK-UP ALARM DOES NOT SOUND...........................................................................................................431 b) BACK-UP ALARM DOES NOT STOP SOUNDING...................................................................................................431 E-4 LAMPS DO NOT LIGHT UP.....................................................................................................................432 a) FRONT LAMPS............................................................................................................................432 b) WORKING LAMPS..........................................................................................................................432 c) REAR LAMPS (RIPPER LAMP)...............................................................................................................434 E-5 WIPER DOES NOT WORK ......................................................................................................................435 E-6 NO WASHER FLUID IS SPRAYED OUT............................................................................................................437 E-7 AIR CONDITIONER HAS NO EFFECT.............................................................................................................439 a) NO AIR COMES OUT.......................................................................................................................439 b) DOES NOT BECOME COOL...................................................................................................................443 E-8 PIN-PULLER CYLINDER DOES NOT WORK (ONLY MACHINES EQUIPPED WITH GIANT RIPPER)..............................................................447 E-9 BLADE PITCH DOES NOT WORK (DUAL TILTDOZER SPECIFICATION)..................................................................................448 E-10 BLADE DUAL TILT DOES NOT WORK (DUAL TILTDOZER SPECIFICATION).............................................................................450 E-11 TORQUE CONVERTER LOCK-UP DOES NOT WORK (TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT LIGHT UP).........................................451 E-12 TORQUE CONVERTER LOCK-UP IS NOT CANCELLED (TORQUE CONVERTER LOCK-UP DISPLAY LAMP STAYS LIGHTED UP).......................................453 a) LOCK-UP DISPLAY LAMP DOES NOT GO OUT...................................................................................................453 b) LOCK-UP DISPLAY LAMP LIGHTS UP BUT LOCK-UP IS NOT ACTUATED.............................................................................453 30 DISASSEMBLY AND ASSEMBLY...............................................................................................................................454 METHOD OF USING MANUAL................................................................................................................................457 PRECAUTIONS WHEN CARRYING OUT OPERATION...............................................................................................................459 SPECIAL TOOL LIST.....................................................................................................................................461 SKETCHES OF SPECIAL TOOLS.............................................................................................................................468 STARTING MOTOR........................................................................................................................................472 REMOVAL...........................................................................................................................................472 INSTALLATION......................................................................................................................................472 ALTERNATOR............................................................................................................................................473 REMOVAL...........................................................................................................................................473 INSTALLATION......................................................................................................................................473 ENGINE OIL COOLER.....................................................................................................................................474 REMOVAL...........................................................................................................................................474 INSTALLATION......................................................................................................................................475 FUEL INJECTION PUMP...................................................................................................................................476 REMOVAL...........................................................................................................................................476 INSTALLATION......................................................................................................................................476 WATER PUMP............................................................................................................................................477 REMOVAL...........................................................................................................................................477 INSTALLATION......................................................................................................................................477 THERMOSTAT............................................................................................................................................478 REMOVAL...........................................................................................................................................478 INSTALLATION......................................................................................................................................478 TURBOCHARGER..........................................................................................................................................479 REMOVAL...........................................................................................................................................479 INSTALLATION......................................................................................................................................480 AFTERCOOLER CORE......................................................................................................................................481 REMOVAL...........................................................................................................................................481 INSTALLATION......................................................................................................................................482 NOZZLE HOLDER.........................................................................................................................................483 REMOVAL...........................................................................................................................................483 INSTALLATION......................................................................................................................................483 ENGINE FRONT SEAL.....................................................................................................................................484 REMOVAL...........................................................................................................................................484 INSTALLATION......................................................................................................................................484 ENGINE REAR SEAL......................................................................................................................................486 REMOVAL...........................................................................................................................................486 INSTALLATION......................................................................................................................................486 CYLINDER HEAD.........................................................................................................................................488 REMOVAL...........................................................................................................................................488 INSTALLATION......................................................................................................................................493 GOVERNOR MOTOR........................................................................................................................................495 REMOVAL...........................................................................................................................................495 INSTALLATION......................................................................................................................................495 IN-LINE SERVO VALVE...................................................................................................................................496 REMOVAL...........................................................................................................................................496 INSTALLATION......................................................................................................................................496 DISASSEMBLY.......................................................................................................................................497 ASSEMBLY..........................................................................................................................................498 FUEL TANK.............................................................................................................................................499 REMOVAL...........................................................................................................................................499 INSTALLATION......................................................................................................................................499 RADIATOR .............................................................................................................................................500 REMOVAL...........................................................................................................................................500 INSTALLATION......................................................................................................................................501 RADIATOR,GUARD........................................................................................................................................502 REMOVAL...........................................................................................................................................502 INSTALLATION......................................................................................................................................504 ENGINE................................................................................................................................................505 REMOVAL...........................................................................................................................................505 INSTALLATION......................................................................................................................................510 DAMPER................................................................................................................................................511 REMOVAL...........................................................................................................................................511 INSTALLATION......................................................................................................................................514 DISASSEMBLY.......................................................................................................................................516 ASSEMBLY..........................................................................................................................................517 POWER TRAIN UNIT......................................................................................................................................519 REMOVAL...........................................................................................................................................519 INSTALLATION......................................................................................................................................523 DISCONNECTION.....................................................................................................................................524 CONNECTION........................................................................................................................................529 PTO...................................................................................................................................................531 DISASSEMBLY.......................................................................................................................................531 ASSEMBLY..........................................................................................................................................535 TORQUE CONVERTER......................................................................................................................................539 DISASSEMBLY.......................................................................................................................................539 ASSEMBLY..........................................................................................................................................544 TORQFLOW TRANSMISSION.................................................................................................................................550 DISASSEMBLY.......................................................................................................................................550 ASSEMBLY..........................................................................................................................................566 STEERING CASE.........................................................................................................................................583 DISASSEMBLY.......................................................................................................................................583 ASSEMBLY..........................................................................................................................................591 POWER TRAIN,LUBRICATION PUMP..........................................................................................................................601 REMOVAL...........................................................................................................................................601 INSTALLATION......................................................................................................................................601 SCAVENGING PUMP.......................................................................................................................................602 REMOVAL...........................................................................................................................................602 INSTALLATION......................................................................................................................................602 TORQUE CONVERTER OIL COOLER...........................................................................................................................603 REMOVAL...........................................................................................................................................603 INSTALLATION......................................................................................................................................603 TORQUE CONVERTER VALVE................................................................................................................................604 REMOVAL...........................................................................................................................................604 INSTALLATION......................................................................................................................................604 DISASSEMBLY.......................................................................................................................................605 ASSEMBLY..........................................................................................................................................607 TRANSMISSION CONTROL VALVE............................................................................................................................608 REMOVAL...........................................................................................................................................608 INSTALLATION......................................................................................................................................608 DISASSEMBLY.......................................................................................................................................609 ASSEMBLY..........................................................................................................................................610 TRANSMISSION LUBRICATION VALVE........................................................................................................................611 REMOVAL...........................................................................................................................................611 INSTALLATION......................................................................................................................................611 DISASSEMBLY.......................................................................................................................................611 ASSEMBLY..........................................................................................................................................611 STEERING CONTROL VALVE................................................................................................................................612 REMOVAL...........................................................................................................................................612 INSTALLATION......................................................................................................................................612 DISASSEMBLY.......................................................................................................................................613 ASSEMBLY..........................................................................................................................................615 FINAL DRIVE ..........................................................................................................................................617 REMOVAL...........................................................................................................................................617 INSTALLATION......................................................................................................................................617 DISASSEMBLY.......................................................................................................................................618 ASSEMBLY..........................................................................................................................................624 TRACK FRAME...........................................................................................................................................633 REMOVAL...........................................................................................................................................633 INSTALLATION......................................................................................................................................635 IDLER.................................................................................................................................................636 REMOVAL...........................................................................................................................................636 INSTALLATION......................................................................................................................................636 DISASSEMBLY.......................................................................................................................................637 ASSEMBLY..........................................................................................................................................639 RECOIL SPRING.........................................................................................................................................641 REMOVAL...........................................................................................................................................641 INSTALLATION......................................................................................................................................646 DISASSEMBLY.......................................................................................................................................647 ASSEMBLY..........................................................................................................................................648 TRACK ROLLER..........................................................................................................................................649 REMOVAL...........................................................................................................................................649 INSTALLATION......................................................................................................................................650 DISASSEMBLY.......................................................................................................................................651 ASSEMBLY..........................................................................................................................................652 BOGIE.................................................................................................................................................654 REMOVAL...........................................................................................................................................654 INSTALLATION......................................................................................................................................655 DISASSEMBLY.......................................................................................................................................656 ASSEMBLY..........................................................................................................................................660 CARRIER ROLLER........................................................................................................................................665 REMOVAL...........................................................................................................................................665 INSTALLATION......................................................................................................................................665 DISASSEMBLY.......................................................................................................................................666 ASSEMBLY..........................................................................................................................................668 TRACK SHOE............................................................................................................................................671 REMOVAL...........................................................................................................................................671 INSTALLATION......................................................................................................................................673 OVERALL DISASSEMBLY OF TRACK SHOE.....................................................................................................................674 OVERALL ASSEMBLY......................................................................................................................................679 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS......................................................................................................693 ONE LINK..............................................................................................................................................694 FIELD DISASSEMBLY.................................................................................................................................694 FIELD ASSEMBLY....................................................................................................................................696 MASTER LINK...........................................................................................................................................698 DISASSEMBLY.......................................................................................................................................698 ASSEMBLY..........................................................................................................................................700 PIVOT SHAFT...........................................................................................................................................703 REMOVAL...........................................................................................................................................703 INSTALLATION......................................................................................................................................703 EQUALIZER BAR.........................................................................................................................................704 REMOVAL...........................................................................................................................................704 INSTALLATION......................................................................................................................................707 EQUALIZER BAR BUSHING.................................................................................................................................708 DISASSEMBLY.......................................................................................................................................708 ASSEMBLY..........................................................................................................................................709 SEGMENT TOOTH.........................................................................................................................................710 REMOVAL...........................................................................................................................................710 INSTALLATION......................................................................................................................................710 HYDRAULIC TANK........................................................................................................................................711 REMOVAL...........................................................................................................................................711 INSTALLATION......................................................................................................................................713 WORK EQUIPMENT,PPC PUMP...............................................................................................................................714 REMOVAL...........................................................................................................................................714 INSTALLATION......................................................................................................................................714 HYDRAULIC COOLER......................................................................................................................................715 REMOVAL...........................................................................................................................................715 INSTALLATION......................................................................................................................................715 BLADE LIFT VALVE......................................................................................................................................716 REMOVAL...........................................................................................................................................716 INSTALLATION......................................................................................................................................717 DISASSEMBLY.......................................................................................................................................718 ASSEMBLY..........................................................................................................................................719 BLADE TILT,RIPPER LO VALVE............................................................................................................................720 REMOVAL...........................................................................................................................................720 INSTALLATION......................................................................................................................................721 DISASSEMBLY.......................................................................................................................................722 ASSEMBLY..........................................................................................................................................722 RIPPER HI VALVE.......................................................................................................................................724 REMOVAL...........................................................................................................................................724 INSTALLATION......................................................................................................................................724 DISASSEMBLY.......................................................................................................................................725 ASSEMBLY..........................................................................................................................................725 PPC CHARGE VALVE......................................................................................................................................727 REMOVAL...........................................................................................................................................727 INSTALLATION......................................................................................................................................727 DISASSEMBLY.......................................................................................................................................728 ASSEMBLY..........................................................................................................................................728 BLADE PPC VALVE.......................................................................................................................................729 REMOVAL...........................................................................................................................................729 INSTALLATION......................................................................................................................................730 DISASSEMBLY.......................................................................................................................................731 ASSEMBLY..........................................................................................................................................732 RIPPER PPC VALVE......................................................................................................................................734 REMOVAL...........................................................................................................................................734 INSTALLATION......................................................................................................................................735 DISASSEMBLY.......................................................................................................................................736 ASSEMBLY..........................................................................................................................................737 BLADE LIFT CYLINDER...................................................................................................................................738 REMOVAL...........................................................................................................................................738 INSTALLATION......................................................................................................................................738 BLADE TILT CYLINDER...................................................................................................................................739 REMOVAL...........................................................................................................................................739 INSTALLATION......................................................................................................................................739 RIPPER LIFT CYLINDER..................................................................................................................................740 REMOVAL...........................................................................................................................................740 INSTALLATION......................................................................................................................................740 RIPPER TILT CYLINDER..................................................................................................................................741 REMOVAL...........................................................................................................................................741 INSTALLATION......................................................................................................................................741 HYDRAULIC CYLINDER....................................................................................................................................742 DISASSEMBLY.......................................................................................................................................742 ASSEMBLY..........................................................................................................................................745 RIPPER PIN-PULLER.....................................................................................................................................748 REMOVAL...........................................................................................................................................748 INSTALLATION......................................................................................................................................748 DISASSEMBLY.......................................................................................................................................749 ASSEMBLY..........................................................................................................................................750 BLADE.................................................................................................................................................752 REMOVAL...........................................................................................................................................752 INSTALLATION......................................................................................................................................753 DISASSEMBLY.......................................................................................................................................754 ASSEMBLY..........................................................................................................................................756 GIANT RIPPER..........................................................................................................................................758 DISASSEMBLY.......................................................................................................................................758 ASSEMBLY..........................................................................................................................................760 ROPS GUARD............................................................................................................................................762 REMOVAL...........................................................................................................................................762 INSTALLATION......................................................................................................................................762 OPERATOR'S CAB........................................................................................................................................763 REMOVAL...........................................................................................................................................763 INSTALLATION......................................................................................................................................763 FLOOR FRAME...........................................................................................................................................764 REMOVAL...........................................................................................................................................764 INSTALLATION......................................................................................................................................768 DASHBOARD.............................................................................................................................................770 REMOVAL...........................................................................................................................................770 INSTALLATION......................................................................................................................................771 MONITOR...............................................................................................................................................772 REMOVAL...........................................................................................................................................772 INSTALLATION......................................................................................................................................772 SHOE SLIP CONTROLLER..................................................................................................................................773 REMOVAL...........................................................................................................................................773 INSTALLATION......................................................................................................................................773 ELECTRIC ENGINE THROTTLE CONTROLLER...................................................................................................................774 REMOVAL...........................................................................................................................................774 INSTALLATION......................................................................................................................................774 TORQUE CONVERTER LOCK-UP CONTROLLER...................................................................................................................775 REMOVAL...........................................................................................................................................775 INSTALLATION......................................................................................................................................775 APS CONTROLLER........................................................................................................................................776 REMOVAL...........................................................................................................................................776 INSTALLATION......................................................................................................................................776 AIR CONDITIONER COMPRESSOR............................................................................................................................777 REMOVAL...........................................................................................................................................777 INSTALLATION......................................................................................................................................778 AIR CONDITIONER CONDENSER.............................................................................................................................779 REMOVAL...........................................................................................................................................779 INSTALLATION......................................................................................................................................779 HOOD..................................................................................................................................................780 REMOVAL...........................................................................................................................................780 INSTALLATION......................................................................................................................................780 40 MAINTENANCE STANDARD...................................................................................................................................781 ENGINE MOUNT..........................................................................................................................................782 DAMPER, UNIVERSAL JOINT...............................................................................................................................783 TORQUE CONVERTER......................................................................................................................................784 TORQUE CONVERTER VALVE................................................................................................................................786 TRANSMISSION..........................................................................................................................................788 TRANSMISSION CONTROL VALVE............................................................................................................................790 POWER TRAIN + LUBRICATION PUMP........................................................................................................................792 SCAVENGING PUMP.......................................................................................................................................793 TRANSFER,BEVEL PINION.................................................................................................................................794 BEVEL GEAR SHAFT,STEERING CLUTCH,BRAKE................................................................................................................795 SEERING CONTROL VALVE.................................................................................................................................797 FINAL DRIVE...........................................................................................................................................799 MAIN FRAME............................................................................................................................................801 TRACK FRAME...........................................................................................................................................803 RECOIL SPRING.........................................................................................................................................804 IDLER.................................................................................................................................................805 TRACK ROLLER BOGIE....................................................................................................................................807 TRACK ROLLER .........................................................................................................................................809 CARRIER ROLLER........................................................................................................................................811 TRACK SHOE............................................................................................................................................813 EQUALIZER BAR.........................................................................................................................................815 PIVOT SHAFT...........................................................................................................................................817 WORK EQUIPMENT + PPC CHARGE PUMP......................................................................................................................819 WORK EQUIPMENT CONTROL VALVE..........................................................................................................................821 PPC VALVE.............................................................................................................................................825 PPC CHARGE VALVE......................................................................................................................................828 WORK EQUIPMENT CYLINDER...............................................................................................................................829 QUICK DROP VALVE......................................................................................................................................833 CYLINDER STAY.........................................................................................................................................834 BLADE.................................................................................................................................................835 RIPPER EQUIPMENT......................................................................................................................................840 90 OTHERS.................................................................................................................................................844 POWER TRAIN HYDRAULIC SYSTEM DRAWING (10-10)..........................................................................................................845 POWER TRAIN HYDRAULIC CIRCUIT DRAWING (10-11).........................................................................................................846 TRANSMISSION (10-31)..................................................................................................................................847 BEVEL GEAR SHAFT,STEERING CLUTCH,BRAKE (10-52)........................................................................................................848 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (TILTDOZER) (10-80)...........................................................................................849 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (10-81)......................................................................................................850 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (DUAL TILTDOZER) (10-82)......................................................................................851 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (DUAL TILTDOZER) (10-83).....................................................................................852 1.BLADE LEVER AT HOLD,RIPPER LEVER AT HOLD (10-116)...................................................................................................853 2.BLADE LEVER AT RAISE (BLADE OPERATING AT HIGH SPEED) (10-118).......................................................................................854 3.BLADE LEVER AT RAISE (BLADE OPERATING AT LOW SPEED) (10-120)........................................................................................855 4.BLADE LEVER AT LEFT TILT (10-122)...................................................................................................................856 5.RIPPER LEVER AT TILT IN (RIPPER LO VALVE,SHUTTLE VALVE ACTUATED) (10-124)...........................................................................857 6.RIPPER LEVER AT TILT IN (RIPPER HI VALVE ACTUATED) (10-126).........................................................................................858 7.RIPPER LEVER AN LOWER (RIPPER LO VALVE,SHUTTLE VALVE ACTUATED) (10-128).............................................................................859 8.BLADE LEVER AT HOLD,RIPPER LEVER AT LOWER (RIPPER HI VALVE ACTUATED) (10-130).......................................................................860 9.RIPPER LEVER AT LOWER (CYLINDER AT STROKE END) (10-132).............................................................................................861 ACTUAL ELECTRIC WIRING DIAGRAM (10-144)...............................................................................................................862 ACTUAL ELECTRIC WIRING DIAGRAM (10-145)...............................................................................................................863 ELECTRIC CIRCUIT DIAGRAM..............................................................................................................................864 CHASSIS ELECTRIC CIRCUIT DIAGRAM (1/2) (10-146)...................................................................................................864 CHASSIS ELECTRIC CIRCUIT DIAGRAM (2/2) (10-147)...................................................................................................865 ELECTRIC CIRCUIT DIAGRAM INSIDE CAB (10-148)......................................................................................................866 CONNECTOR ARRANGEMENT DIAGRAM (20-116)................................................................................................................867 CONNECTOR ARRANGEMENT DIAGRAM (20-117)................................................................................................................868 BEVEL GEAR SHAFT,STEERING CLUTCH,BRAKE (40-16)........................................................................................................869
PLEASE NOTE:
- This is the SAME exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
1 review for Komatsu D375A-3 17001 and up Crawler Bulldozer Shop Manual – PDF DOWNLOAD
Add a review
Moshe Ahmed –
My engine simply wont start. Any help?