Komatsu D375A-3 Bulldozer Shop Manual SEBM026600 – PDF DOWNLOAD 

Description

Komatsu D375A-3 Bulldozer Shop Manual SEBM026600 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D375A-3 Bulldozer Shop Manual SEBM026600 – PDF DOWNLOAD 

Language : English
Pages : 723
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu D375A-3 Bulldozer Shop Manual SEBM026600 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
D375A-3                     17736 and up 

COVER 1
CONTENTS 2
01 GENERAL 23
SPECIFICATION DIMENSION DRAWINGS 24
SPECIFICATIONS 26
WEIGHT TABLE 31
TABLE OF FUEL,COOLANT AND LUBRICANTS 33
10 STRUCTURE AND FUNCTION 35
ENGINE CONTROL 36
POWER TRAIN 37
OVERALL DRAWING OF POWER TRAIN UNIT 39
POWER TRAIN HYDRAULIC PIPING DIAGRAM 41
POWER TRAIN HYDRAULIC CIRCUIT DRAWING 42
DAMPER,UNIVERSAL JOINT 44
TORQUE CONVERTER,PTO 46
TORQUE CONVERTER VALVE 51
TRANSMISSION CONTROL 53
TRANSMISSION 54
TRANSMISSION CONTROL VALVE 61
TRANSMISSION LUBRICATION RELIEF VALVE 68
SCAVENGING PUMP STRAINER 69
OVERFLOW VALVE 70
POWER TRAIN PUMP STRAINER 72
POWER TRAIN,LUBRICATING OIL FILTER 73
STEERING,BRAKE CONTROL 74
TRANSFER,BEVEL GEAR SHAFT,STEERING 78
STEERING CONTROL VALVE 82
FINAL DRIVE 90
TRACK FRAME 94
RECOIL SPRING 96
TRACK ROLLER BOGIE 97
MAIN FRAME 99
SUSPENSION 100
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 102
PPC CONTROL PIPING DIAGRAM 106
WORK EQUIPMENT CONTROL 107
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 109
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 111
HYDRAULIC TANK 113
PPC CHARGE VALVE 114
ACCUMULATOR 116
PPC LOCK VALVE 117
PPC VALVE 118
PISTON VALVE 128
QUICK DROP VALVE 129
PIN PULLER SWITCH 130
PIN PULLER SOLENOID VALVE 131
BLADE CONTROL KNOB 133
PITCH,DUAL TILT SOLENOID VALVE 134
MAIN CONTROL VALVE 136
CYLINDER STAY 162
BLADE 163
RIPPER 165
CAB MOUNT 167
CAB 168
AIR CONDITIONER 170
MONITOR SYSTEM 171
SWITCH PANEL 179
FUSE BOX 179
ENGINE START SAFETY SYSTEM 181
APS 182
20 TESTING AND ADJUSTING 184
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 185
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 186
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS 191
STANDARD VALUE TABLE FOR MONITOR 192
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 193
MEASURING ENGINE SPEED 194
MEASURING EXHAUST COLOR 195
ADJUSTING VALVE CLEARANCE 196
MEASURING COMPRESSION PRESSURE 197
MEASURING BLOW-BY PRESSURE 198
MEASURING ENGINE OIL PRESSURE 199
TESTING AND ADJUSTING FUEL INJECTION TIMING 200
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 202
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 202
MEASURING EXHAUST TEMPERATURE 203
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE ) 204
MEASURING TORQUE CONVERTER STALL SPEED 205
MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL) 206
ADJUSTING FUEL CONTROL LINKAGE 207
ADJUSTING DECELERATOR PEDAL 210
ADJUSTING JOYSTICK (STEERING, DIRECTIONAL, SPEED CONTROL LEVER), PARKING BRAKE LEVER LINKAGE 211
ADJUSTING BRAKE PEDAL LINKAGE 215
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE 216
MEASURING POWER TRAIN OIL PRESSURE 217
MEASURING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 220
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE 222
MEASURING PPC VALVE OUTPUT PRESSURE 223
ADJUSTING PPC VALVE 224
MEASURING ON-OFF SOLENOID VALVE OUTPUT PRESSURE 225
BLEEDING AIR FROM HYDRAULIC CYLINDERS 226
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 226
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER 227
MEASURING LEAKAGE INSIDE CYLINDER 228
ADJUSTING SEMI U-TILTDOZER 229
ADJUSTING CLEARANCE OF IDLER 231
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE 232
TROUBLESHOOTING 233
POINTS TO REMEMBER WHEN TROUBLESHOOTING 234
SEQUENCE OF EVENTS IN TROUBLESHOOTING 235
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 236
CHECKS BEFORE TROUBLESHOOTING 244
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 245
CONNECTOR ARRANGEMENT DIAGRAM 247
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 251
METHOD OF USING TROUBLESHOOTING CHARTS 261
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 263
METHOD OF USING TROUBLESHOOTING CHARTS 264
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 268
S-2 ENGINE DOES NOT START 269
1) ENGINE DOES NOT TURN 269
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 270
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 271
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 272
S-4 ENGINE STOPS DURING OPERATIONS 273
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 274
S-6 ENGINE LACKS OUTPUT (NO POWER ) 275
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) 276
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 277
S-9 OIL BECOMES CONTAMINATED QUICKLY 278
S-10 FUEL CONSUMPTION IS EXCESSIVE 279
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 280
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 281
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL ) 282
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 283
S-15 ABNORMAL NOISE IS MADE 284
S-16 VIBRATION IS EXCESSIVE 285
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) 286
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS) 287
H-1 MACHINE LACKS POWER (LACKS DRAWBAR PULL) 289
H-2 MACHINE DOES NOT MOVE (2ND, 3RD, ENGINE RUNNING) 291
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE 293
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE) 295
H-5 TIME LAG IS EXCESSIVE WHEN SHIFTING GEAR OR CHANGING DIRECTION 296
H-6 MACHINE DOES NOT TURN (CAN TRAVEL IN STRAIGHT LINE) 297
H-7 MACHINE TURNS ONLY IN ONE DIRECTION (LEFT OR RIGHT) [JOYSTICK (STEERING, DIRECTIONAL, SPEED LEVER) OPERATED] 298
H-8 MACHINE TURNS TOO FAR 299
H-9 BRAKES DO NOT WORK 300
H-10 POWER TRAIN OIL OVERHEATS 301
H-101 ALL WORK EQUIPMENT SPEEDS ARE SLOW 303
H-102 WORK EQUIPMENT DOES NOT MOVE 305
H-103 BLADE LIFT SPEED IS SLOW OR LACKS POWER 306
H-104 BLADE TILT SPEED IS SLOW OR LACKS POWER 306
H-105 RIPPER LIFT SPEED IS SLOW OR LACKS POWER 307
H-106 RIPPER TILT SPEED IS SLOW OR LACKS POWER 307
H-107 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 308
H-108 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 308
H-109 EXCESSIVE HYDRAULIC DRIFT OF RIPPER 309
H-110 PIN-PULLER CYLINDER DOES NOT WORK 309
H-111 BLADE PITCH DOES NOT WORK 310
H-112 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP 310
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 311
M-1 WHEN STARTING SWITCH IN TURNED ON, NO DISPLAY IS GIVEN ON MONITOR PANEL 312
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL LIGHT UP BUT DO NOT GO OUT 312
M-3 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR IN ENGINE) 313
a) (BATTERY CHARGE) FLASHES 313
b) (ENGINE OIL PRESSURE) FLASHES 313
c) (COOLANT TEMPERATURE) FLASHES 314
d) (POWER TRAIN OIL TEMPERATURE) FLASHES 315
M-4 ABNORMALITY IN (PREHEATING) 316
a) PREHEATING MONITOR LAMP DOES NOT LIGHT UP 316
b) PREHEATING MONITOR LAMP STAYS LIGHTED UP 316
M-5 ABNORMALITY IN BUZZER 317
a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND OR BUZZER DOES NOT SOUND FOR 1 SEC WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) 317
b) MONITOR DISPLAY IS NORMAL BUT BUZZER SOUNDS 317
M-6 ABNORMALITY IN WARNING LAMP 318
a) CAUTION ITEM FLASHES BUT WARNING LAMP DOES NOT FLASH, OR WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 1 SECOND 318
b) MONITOR DISPLAY IS NORMAL BUT WARNING LAMP LIGHTS UP 318
M-7 ABNORMALITY IN GAUGE 319
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE 319
b) ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE 319
c) ABNORMALITY IN FUEL LEVEL GAUGE 320
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED 321
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMP, WORKING LAMP ARE NORMAL) 322
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 323
E-1 ENGINE DOES NOT START 324
E-2 DEFECTIVE OPERATION OF APS 326
a) PREHEATING MONITOR LAMP DOES NOT LIGHT UP DURING PREHEATING 326
b) PREHEATING MONITOR LAMP STAYS LIGHTED UP AFTER PREHEATING IS COMPLETED 326
c) PREHEATING MONITOR LAMP FLASHES AFTER PREHEATING IS COMPLETED 327
d) PREHEATING MONITOR LAMP LIGHTS UP WHEN ENGINE IS STARTED (STARTING SWITCH AT START) AFTER PREHEATING IS COMPLETED 327
e) APS IS NOT ACTUATED WHEN WATER TEMPERATURE IS BELOW 20℃ 328
f) APS IS ACTUATED WHEN WATER TEMPERATURE IS ABOVE 20℃ 330
g) APS IS ACTUATED WHEN WATER TEMPERATURE IS BELOW 20℃ BUT APS SWITCH IS NOT TURNED ON 330
E-3 DEFECTIVE OPERATION OF BACK-UP ALARM 331
a) BACK-UP ALARM DOES NOT SOUND 331
b) BACK-UP ALARM DOES NOT STOP SOUNDING 331
E-4 LAMPS DO NOT LIGHT UP 332
a) FRONT LAMPS 332
b) WORKING LAMPS 332
c) REAR LAMPS (RIPPER LAMP) 334
E-5 PIN-PULLER CYLINDER DOES NOT WORK (ONLY MACHINES EQUIPPED WITH GIANT RIPPER) 335
E-6 BLADE DUAL TILT DOES NOT WORK (DUAL TILTDOZER SPECIFICATION) 336
E-7 BLADE PITCH DOES NOT WORK (DUAL TILTDOZER SPECIFICATION) 337
30 DISASSEMBLY AND ASSEMBLY 339
METHOD OF USING MANUAL 342
PRECAUTIONS WHEN CARRYING OUT OPERATION 344
SPECIAL TOOL LIST 346
SKETCHES OF SPECIAL TOOLS 353
STARTING MOTOR 357
REMOVAL 357
INSTALLATION 357
ALTERNATOR 358
REMOVAL 358
INSTALLATION 358
ENGINE OIL COOLER 359
REMOVAL 359
INSTALLATION 360
FUEL INJECTION PUMP 361
REMOVAL 361
INSTALLATION 361
WATER PUMP 362
REMOVAL 362
INSTALLATION 362
THERMOSTAT 363
REMOVAL 363
INSTALLATION 363
TURBOCHARGER 364
REMOVAL 364
INSTALLATION 365
AFTERCOOLER CORE 366
REMOVAL 366
INSTALLATION 367
NOZZLE HOLDER 368
REMOVAL 368
INSTALLATION 368
ENGINE FRONT SEAL 369
REMOVAL 369
INSTALLATION 369
ENGINE REAR SEAL 371
REMOVAL 371
INSTALLATION 371
CYLINDER HEAD 373
REMOVAL 373
INSTALLATION 378
FUEL TANK 380
REMOVAL 380
INSTALLATION 380
RADIATOR 381
REMOVAL 381
INSTALLATION 382
RADIATOR GUARD 383
REMOVAL 383
INSTALLATION 385
ENGINE 386
REMOVAL 386
INSTALLATION 391
DAMPER 392
REMOVAL 392
INSTALLATION 395
DISASSEMBLY 397
ASSEMBLY 398
POWER TRAIN UNIT 400
REMOVAL 400
INSTALLATION 404
DISCONNECTION 405
CONNECTION 410
PTO 412
DISASSEMBLY 412
ASSEMBLY 416
TORQUE CONVERTER 420
DISASSEMBLY 420
ASSEMBLY 426
TORQFLOW TRANSMISSION 432
DISASSEMBLY 432
ASSEMBLY 448
STEERING CASE 465
DISASSEMBLY 465
ASSEMBLY 473
POWER TRAIN, LUBRICATION PUMP 483
REMOVAL 483
INSTALLATION 483
SCAVENGING PUMP 484
REMOVAL 484
INSTALLATION 484
TORQUE CONVERTER OIL COOLER 485
REMOVAL 485
INSTALLATION 485
TORQUE CONVERTER VALVE 486
REMOVAL 486
INSTALLATION 486
DISASSEMBLY 487
ASSEMBLY 488
TRANSMISSION CONTROL VALVE 489
REMOVAL 489
INSTALLATION 489
DISASSEMBLY 490
ASSEMBLY 491
TRANSMISSION LUBRICATION VALVE 492
REMOVAL 492
INSTALLATION 492
DISASSEMBLY 492
ASSEMBLY 492
STEERING CONTROL VALVE 493
REMOVAL 493
INSTALLATION 493
DISASSEMBLY 494
ASSEMBLY 496
FINAL DRIVE 497
REMOVAL 497
INSTALLATION 497
DISASSEMBLY 498
ASSEMBLY 504
TRACK FRAME 513
REMOVAL 513
INSTALLATION 515
IDLER 516
REMOVAL 516
INSTALLATION 516
DISASSEMBLY 517
ASSEMBLY 519
RECOIL SPRING 521
REMOVAL 521
INSTALLATION 526
DISASSEMBLY 527
ASSEMBLY 528
TRACK ROLLER 529
REMOVAL 529
INSTALLATION 530
DISASSEMBLY 531
ASSEMBLY 532
BOGIE 534
REMOVAL 534
INSTALLATION 535
DISASSEMBLY 536
ASSEMBLY 540
CARRIER ROLLER 545
REMOVAL 545
INSTALLATION 545
DISASSEMBLY 546
ASSEMBLY 548
TRACK SHOE 551
REMOVAL 551
INSTALLATION 553
OVERALL DISASSEMBLY OF TRACK SHOE 554
OVERALL ASSEMBLY 559
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 573
ONE LINK 574
FIELD DISASSEMBLY 574
FIELD ASSEMBLY 576
MASTER LINK 578
DISASSEMBLY 578
ASSEMBLY 580
PIVOT SHAFT 583
REMOVAL 583
INSTALLATION 583
EQUALIZER BAR 584
REMOVAL 584
INSTALLATION 587
EQUALIZER BAR BUSHING 588
DISASSEMBLY 588
ASSEMBLY 589
SEGMENT TOOTH 590
REMOVAL 590
INSTALLATION 590
HYDRAULIC TANK 591
REMOVAL 591
INSTALLATION 593
WORK EQUIPMENT, PPC PUMP 594
REMOVAL 594
INSTALLATION 594
BLADE LIFT VALVE 595
REMOVAL 595
INSTALLATION 596
DISASSEMBLY 597
ASSEMBLY 598
BLADE TILT, RIPPER LO VALVE 599
REMOVAL 599
INSTALLATION 600
DISASSEMBLY 601
ASSEMBLY 601
RIPPER HI VALVE 603
REMOVAL 603
INSTALLATION 603
DISASSEMBLY 604
ASSEMBLY 604
PPC CHARGE VALVE 606
REMOVAL 606
INSTALLATION 606
DISASSEMBLY 607
ASSEMBLY 607
BlADE PPC VALVE 608
REMOVAL 608
INSTALLATION 609
DISASSEMBLY 610
ASSEMBLY 611
RIPPER PPC VALVE 613
REMOVAL 613
INSTALLATION 614
DISASSEMBLY 615
ASSEMBLY 616
BlADE LIFT CYLINDER 617
REMOVAL 617
INSTALLATION 617
BlADE TILT CYLINDER 618
REMOVAL 618
INSTALLATION 618
RIPPER LIFT CYLINDER 619
REMOVAL 619
INSTALLATION 619
RIPPER TILT CYLINDER 620
REMOVAL 620
INSTALLATION 620
HYDRAULIC CYLINDER 621
DISASSEMBLY 621
ASSEMBLY 624
RIPPER PIN-PULLER 627
REMOVAL 627
INSTALLATION 627
DISASSEMBLY 628
ASSEMBLY 629
BLADE 631
REMOVAL 631
INSTALLATION 632
DISASSEMBLY 633
ASSEMBLY 635
GIANT RIPPER 637
DISASSEMBLY 637
ASSEMBLY 639
ROPS GUARD 641
REMOVAL 641
INSTALLATION 641
OPERATOR’S CAB 642
REMOVAL 642
INSTALLATION 642
FLOOR FRAME 643
REMOVAL 643
INSTALLATION 647
DASHBOARD 649
REMOVAL 649
INSTALLATION 650
MONITOR PANEL 651
REMOVAL 651
INSTALLATION 651
APS CONTROLLER 652
REMOVAL 652
INSTALLATION 652
AIR CONDITIONER COMPRESSOR 653
REMOVAL 653
INSTALLATION 654
AIR CONDITIONER CONDENSER 655
REMOVAL 655
INSTALLATION 655
HOOD 656
REMOVAL 656
INSTALLATION 656
40 MAINTENANCE STANDARD 657
ENGINE MOUNT 658
DAMPER, UNIVERSAL JOINT 659
TORQUE CONVERTER 660
TORQUE CONVERTER VALVE 661
TRANSMISSION 662
TRANSMISSION CONTROL VALVE 664
POWER TRAIN LUBRICATION + POWER TRAIN PUMP 666
SCAVENGING PUMP 667
TRANSFER, BEVEL PINION 668
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE 669
STEERING CONTROL VALVE 671
FINAL DRIVE 673
MAIN FRAME 675
TRACK FRAME 677
RECOIL SPRING 678
IDLER 679
TRACK ROLLER BOGIE 681
TRACK ROLLER 683
CARRIER ROLLER 685
TRACK SHOE 687
SINGLE SHOE 690
EQUALIZER BAR 691
PIVOT SHAFT 693
WORK EQUIPMENT + PPC CHARGE PUMP 695
WORK EQUIPMENT CONTROL VALVE 697
PPC VALVE 701
PPC CHARGE VALVE 704
WORK EQUIPMENT CYLINDER 705
QUICK DROP VALVE 709
CLINDER STAY 710
BLADE 711
RIPPER EQUIPMENT 716
90 OTHERS 720
ELECTRICAL CIRCUIT DIAGRAM 721

DESCRIPTION:

Komatsu D375A-3 Bulldozer Shop Manual SEBM026600 – PDF DOWNLOAD

MACHINE MODEL    SERIAL NUMBER
D375A-3                     17736 and up 

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

PRECAUTIONS DURING WORK :

IMAGES PREVIEW OF THE MANUAL:

S.V  25/12/24