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Komatsu D375A-3 Crawler Bulldozer Shop Manual SEBM016104 – PDF DOWNLOAD
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Komatsu D375A-3 Crawler Bulldozer Shop Manual
MACHINE MODEL SERIAL NUMBER
D375A-3 17501 and up
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Description
Komatsu D375A-3 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D375A-3 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D375A-3
Serial Number: 17501 and up
Book Code: SEBM016104
Language: English
Pages: 891
File Format: Portable Document Format (PDF)
KOMATSU D375A-3 CRAWLER BULLDOZER SHOP MANUAL SEBM016104 – PDF DOWNLOAD:
DESCRIPTION:
Komatsu D375A-3 Crawler Bulldozer Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
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. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu D375A-3 Crawler Bulldozer Shop Manual
MAIN MENU........................................................................................................................................ 0 COVER PAGE....................................................................................................................................... 1 CONTENTS......................................................................................................................................... 2 00 FORWARD....................................................................................................................................... 7 HOW TO READ A SHOP MANUAL.................................................................................................................... 10 HOISTING INSTRUCTIONS........................................................................................................................ 11 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER................................................................................... 12 COATING MATERIALS............................................................................................................................ 14 STANDARD TIGHTENING TORQUE................................................................................................................... 16 ELECTRIC WIRE CODE........................................................................................................................... 19 CONVERSION TABLE............................................................................................................................. 20 UNITS........................................................................................................................................ 26 01 GENERAL...................................................................................................................................... 27 SPECIFICATION DIMENSION DRAWINGS............................................................................................................. 28 SPECIFICATIONS............................................................................................................................... 30 WEIGHT TABLE................................................................................................................................. 35 TABLE OF FUEL, COOLANT AND LUBRICANTS........................................................................................................ 37 10 STRUCTURE AND FUNCTION....................................................................................................................... 38 ENGINE CONTROL............................................................................................................................... 39 POWER TRAIN.................................................................................................................................. 41 OVERALL DRAWING OF POER TRAIN UNIT........................................................................................................... 43 POWER TRAIN HYDRAULIC PIPING DRAWING......................................................................................................... 45 POWER TRAIN SYSTEM DRAWING................................................................................................................... 46 POWER TRAIN HYDRAULIC CIRCUIT DRAWING........................................................................................................ 47 DAMPER, UNIVERSAL JOINT...................................................................................................................... 49 TORQUE CONVERTER, PTO........................................................................................................................ 51 TORQUE CONVERTER VALVE....................................................................................................................... 56 TRANSMISSION CONTROL......................................................................................................................... 65 TRANSMISSION................................................................................................................................. 66 TRANSMISSION CONTROL VALVE................................................................................................................... 73 TRANSMISSION LUBRICATION RELIEF VALVE........................................................................................................ 80 SCAVENGING PUMP STRAINER..................................................................................................................... 81 POWER TRAIN PUMP STRAINER.................................................................................................................... 82 POWER TRAIN, LUBRICATING OIL FILTER.......................................................................................................... 83 STEERING, BRAKE CONTROL...................................................................................................................... 84 TRANSFER, BEVEL GEAR SHAFT, STEERING......................................................................................................... 88 STEERING CONTROL VALVE....................................................................................................................... 92 FINAL DRIVE..................................................................................................................................100 TRACK FRAME..................................................................................................................................104 RECOIL SPRING................................................................................................................................106 TRACK ROLLER BOGIE...........................................................................................................................107 MAIN FRAME...................................................................................................................................109 SUSPENSION...................................................................................................................................110 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM......................................................................................................112 PPC CONTROL PIPING DIAGRAM...................................................................................................................116 WORK EQUIPMENT CONTROL.......................................................................................................................117 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (TILTDOZER)..........................................................................................119 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................120 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (DUALTILTDOZER)......................................................................................122 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....................................................................................................123 HYDRAULIC TANK...............................................................................................................................125 PPC CHARGE VALVE.............................................................................................................................126 ACCUMULATOR..................................................................................................................................128 PPC LOCK VALVE...............................................................................................................................129 PPC VALVE....................................................................................................................................130 PISTON VALVE.................................................................................................................................140 QUICK DROP VALVE.............................................................................................................................141 PIN PULLER SWITCH............................................................................................................................142 PIN PULLER SOLENOID VALVE....................................................................................................................143 BLADE CONTROL KNOB...........................................................................................................................145 PITCH, DUAL TILT SOLENOID VALVE..............................................................................................................146 MAIN CONTROL VALVE...........................................................................................................................148 CYLINDER STAY................................................................................................................................173 BLADE........................................................................................................................................174 RIPPER.......................................................................................................................................176 CAB MOUNT....................................................................................................................................178 CAB..........................................................................................................................................179 AIR CONDITIONER..............................................................................................................................181 ACTUAL ELECTRIC WIRING DIAGRAM...............................................................................................................182 ELECTRIC CIRCUIT DIAGRAM.....................................................................................................................185 MACHINE MONITOR SYSTEM.......................................................................................................................188 MODE SELECTION SYSTEM........................................................................................................................196 ENGINE CONTROL SYSTEM........................................................................................................................205 SWITCH PANEL.................................................................................................................................213 FUSE BOX.....................................................................................................................................213 ENGNE START SAFETY SYSTEM....................................................................................................................215 APS..........................................................................................................................................216 TORQUE CONVERTER LOCK-UP CONTROL SYSTEM......................................................................................................218 20 TESTING AND ADJUSTING........................................................................................................................222 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS................................................................................................223 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS...............................................................................................224 STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS............................................................................................230 STANDARD VALUE TABLE FOR MACHINE MONITOR.....................................................................................................237 TESTING AND ADJUSTING........................................................................................................................241 TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING...............................................................................242 MEASURING ENGINE SPEED...................................................................................................................243 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)...........................................................................................244 MEASURING EXHAUST TEMPERATURE............................................................................................................245 MEASURING EXHAUST COLOR..................................................................................................................246 ADJUSTING VALVE CLEARANCE................................................................................................................247 MEASURING COMPRESSION PRESSURE...........................................................................................................248 MEASURING BLOW-BY PRESSURE...............................................................................................................249 MEASURING ENGINE OIL PRESSURE............................................................................................................250 TESTING AND ADJUSTING FUEL INJECTION TIMING..............................................................................................251 TESTING AND ADJUSTING ALTERNATOR BELT TENSION............................................................................................253 TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONING COMPRESSOR.......................................................................253 TESTING AND REPLACING FAN BELT AND ADJUSTING AUTO TENSIONER..............................................................................254 ADJUSTING FUEL CONTROL LEVER AND DECELERATOR PEDAL.......................................................................................256 MEASURING TORQUE CONVERTER STALL SPEED...................................................................................................262 MEASURING TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL) SPEED..............................................................263 MEASURING POWER TRAIN OIL PRESSURE.......................................................................................................264 SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE...........................................................................................267 ADJUSTING FULL MONOLEVER AND PARKING LEVER...............................................................................................268 ADJUSTING BRAKE PEDAL LINKAGE............................................................................................................273 ADJUSTING CLEARANCE OF IDLER.............................................................................................................275 CHECKING WEAR OF SPROCKET................................................................................................................276 TESTING AND ADJUSTING TRACK SHOE TENSION.................................................................................................277 MEASURING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE................................................................................278 TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE............................................................................280 MEASURING PPC VALVE OUTPUT PRESSURE......................................................................................................282 ADJUSTING PPC VALVE......................................................................................................................284 MEASURING OUTPUT PRESSURE OF RIPPER PIN-PULLER SOLENOID VALVE............................................................................285 CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER........................................................................286 MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER..............................................................................................287 RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT........................................................................................288 BLEEDING AIR FROM HYDRAULIC CYLINDERS....................................................................................................288 ADJUSTING WORK EQUIPMENT SAFETY LEVER....................................................................................................289 ADJUSTING SEMI U-TILTDOZER...............................................................................................................290 TROUBLESHOOTING..............................................................................................................................292 POINTS TO REMEMBER.......................................................................................................................293 SEQUENCE OF EVENTS IN TROUBLESHOOTING....................................................................................................294 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.........................................................................................295 CHECKS BEFORE TROUBLESHOOTING............................................................................................................303 TYPE OF CONNECTOR AND POSITION OF INSTALLATION...........................................................................................304 CONNECTOR ARRANGEMENT DIAGRAM............................................................................................................306 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS...............................................................................................310 METHOD OF USING TROUBLESHOOTING CHARTS...................................................................................................320 MODE SELECTION SYSTEM....................................................................................................................322 TABLE CONTROLLER LED DISPLAYS............................................................................................................324 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)................................................................................................325 METHOD OF USING TROUBLESHOOTING CHARTS...............................................................................................326 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).......................................................................330 S-2 ENGINE DOES NOT START...........................................................................................................331 1) ENGINE DOES NOT TURN.........................................................................................................331 2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED).....................................................332 3) EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...................................................333 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)............................................................................334 S-4 ENGINE STOPS DURING OPERATIONS..................................................................................................335 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING).......................................................................................336 S-6 ENGINE LACKS OUTPUT (NO POWER)..................................................................................................337 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)..................................................................................338 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE).........................................................................339 S-9 OIL BECOMES CONTAMINATED QUICKLY................................................................................................340 S-10 FUEL CONSUMTPION IS EXCESSIVE..................................................................................................341 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN........................................................342 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE).....................................................................343 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)...........................................................................................344 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)...............................................................................345 S-15 ABNORMAL NOISE IS MADE.........................................................................................................346 S-16 VIBRATION IS EXCESSIVE.........................................................................................................347 TROUBLESHOOTING OF ELECTRICAL SYSTEM (M0DE SELECTION ELECTRONIC SYSTEM) (ES MODE)........................................................348 ELECTRICAL CIRCUIT DIAGRAM FOR ES MODE...............................................................................................349 ES-1 TORQUE CONVERTER LOCK-UP DOES NOT WORK (LOCK-UP DISPLAY LAMP DOES NOT LIGHT UP).................................................353 ES-2 TORQUE CONVERTER L0CK-UP REMAINS ENGAGED (LOCK-UP DISPLAY LAMP DOES NOT GO OUT).................................................356 ES-3 MODE DOES NOT SWITCH WHEN ECONOMY MODE SWITCH IS TURNED ON (SWITCH LED IS NORMAL)...............................................358 ES-4 REVERSE SLOW IS NOT ACTUATED WHEN REVERSE SLOW SWITCH IS TURNED ON (SWITCH LED IS NORMAL).......................................361 ES-5 SHOE SLIP CONTROL IS NOT ACTUATED WHEN SHOE SLIP CONTROL SWITCH IS TURNED ON (SWITCH LED IS NORMAL).............................362 ES-6 SELECTED LEVEL DOES NOT CHANGE WHEN ROCKBED SELECTION SWITCH IS PRESSED (SWITCH LED IS NORMAL)..................................365 ES-7 ENGINE CANNOT BE CONTROLLED, ENGINE CANNOT BE STARTED, ENGINE STALLS (WHEN SHOE SLIP CONTROL IS ON).............................368 ES-8 SHOE SLIP IS NOT DETECTED WHEN SHOE CLIP CONTROL IS ON..........................................................................370 ES-9 STARTING MODULATION DOES NOT WORK WHEN SHOE CONTROL IS ON.......................................................................371 ES-10 THERE IS NO UP/DOWN OF DRAWBAR PULL BY USING RIPPER LEVER WHEN SHOE SLIP CONTROL IS ON.........................................371 ES-11 ABNORMALITY IN RIPPER LEVER SIGNAL AND JOYSTICK DIRECTIONAL SIGNAL.............................................................372 TROUBLESHOOTING OF SHOE SLIP CONTROLLER, ELECTRIC ENGINE THROTTLE CONTROLLER SYSTEM (G MODE).............................................376 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE...........................................................377 ELECTRICAL CIRCUIT DIAGRAM OF G MODE.................................................................................................383 G-1 (ABNORMALITY IN ENGINE) IS DISPLAYED.............................................................................................386 G-2 (ABNORMALITY IN ACCELERATION SENSOR POWER SOURCE) IS DISPLAYED...................................................................387 G-3 (ABNORMALITY IN TORQUE CONVERTER SPEED SENSOR) IS DISPLAYED......................................................................388 G-4 (ABNORMALITY IN ENGINE SPEED SENSOR) IS DISPLAYED................................................................................389 G-5 (ABNORMALITY IN ECONOMY MODE SELECTION) IS DISPLAYED.............................................................................390 G-6 (ABNORMALITY IN CONTROL MODE) IS DISPLAYED.......................................................................................391 G-7 (ABNORMALITY IN ACCELERATION SENSOR) IS DISPLAYED................................................................................392 G-8 (ABNORMALITY IN RIPPING MODE SELECTION) IS DISPLAYED.............................................................................393 G-9 (ABNORMALITY IN MANUAL POTENTIOMETER) IS DISPLAYED...............................................................................394 G-10 (SHORT CIRCUIT IN GOVERNOR MOTOR SYSTEM) IS DISPLAYED...........................................................................395 G-11 (DISCONNECTION IN GOVERNOR MOTOR SYSTEM) IS DISPLAYED...........................................................................396 G-12 (ABNORMALITY IN FEEDBACK POTENTIOMETER) IS DISPLAYED............................................................................397 G-13 (ABNORMALITY IN SHOE SLIP CONTROL COMMAND) IS DISPLAYED.........................................................................399 G-14 (ABNORMALITY IN SHOE SLIP CONTROLLER) IS DISPLAYED..............................................................................400 G-15 (ABNORMALITY IN POWER SOURCE) IS DISPLAYED......................................................................................401 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE).............................................................................402 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS).................................................................403 H-1 MACHINE LACKS POWER (LACKS DRAWBAR PULL)........................................................................................405 H-2 MACHINE DOES NOT MOVE (2ND, 3RD, ENGINE RUNNING)................................................................................407 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE........................................................................................409 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE)...................................................................411 H-5 TIME LAG IS EXCESSIVE WHEN SHIFTING GEAR OR CHANGING DIRECTION..................................................................412 H-6 MACHINE DOES NOT TURN (CAN TRAVEL IN STAIGHT LINE)..............................................................................413 H-7 MACHINE TURNS ONLY IN ONE DIRECTION (LEFT OR RIGHT) [JOYSTICK (STEERING, DIRECTIONAL, SPEED LEVER) OPERATED]...................414 H-8 MACHINE TURNS TOO FAR...........................................................................................................415 H-9 BRAKES DO NOT WORK..............................................................................................................416 H-10 TORQUE CONVERTER LOCK-UP DOES NOT WORK.........................................................................................416 H-11 POWER TRAIN OIL OVERHEATS......................................................................................................417 H-101 ALL WORK EQUIPMENT SPEEDS ARE SLOW............................................................................................419 H-102 WORK EQUIPMENT DOES NOT MOVE..................................................................................................421 H-103 BLADE LIFT SPEED IS SLOW OR LACKS POWER.......................................................................................422 H-104 BLADE TILT SPEED IS SLOW OR LACKS POWER.......................................................................................422 H-105 RIPPER LIFT SPEED IS SLOW OR LACKS POWER......................................................................................423 H-106 RIPPER TILT SPEED IS SLOW OR LACKS POWER......................................................................................423 H-107 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT.......................................................................................424 H-108 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT.......................................................................................424 H-109 EXCESSIVE HYDRAULIC DRIFT OF RIPPER...........................................................................................425 H-110 PIN-PULLER CYLINDER DOES NOT WORK.............................................................................................425 H-111 BLADE PITCH DOES NOT WORK.....................................................................................................426 H-112 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP.....................................................................................426 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE).......................................................................................427 RELATED ELECTRICAL CIRCUIT DIAGRAM FOR M MODE........................................................................................428 M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN ON MONITOR PANEL.........................................................429 M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL LIGHT UP BUT DO NOT GO OUT...........................................429 M-3 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CHECK ITEMS FLASH...........................................................430 A) RADIATOR WATER LEVEL FLASHES.................................................................................................430 B) (ENGINE OIL LEVEL) FLASHES...................................................................................................430 M-4 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED), CAUTION ITEMS FLASH (BATTERY CHARGE, ENGINE OIL PRESSURE DO NOT LIGH........431 A) ALTERNATOR SYSTEM............................................................................................................431 B) ENGINE OIL PRESSURE SENSOR SYSTEM............................................................................................432 M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN TEHRE IS NO ABNORMALITY IN CHECK ITEM........433 A) (BATTERY CHARGE) FLASHES.....................................................................................................433 B) (ENGINE OIL PRESSURE) FLASHES...............................................................................................433 C) (RADIATOR WATER LEVEL) FLASHES...............................................................................................434 D) (COOLANT TEMPERATURE) FLASHES................................................................................................434 E) (POWER TRAIN OIL TEMPERATURE) FLASHES........................................................................................435 F) (HYDRAULIC OIL TEMPERATURE) FLASHES..........................................................................................435 M-6 ABNORMALITY IN (PREHEATING).....................................................................................................436 A) PREHEATING MONITOR LAMP DOES NOT LIGHT UP....................................................................................436 B) PREHEATING MONITOR LAMP STAYS LIGHTED UP.....................................................................................436 M-7 ABNORMALITY IN BUZZER...........................................................................................................437 A) CAUTION ITME FLASHES BUT BUZZER DOES NOT SOUND OR BUZZER DOES NOT SOUND FOR 1 SEC. WHEN STARTING SWITCH IS TURNED ON (ENG....437 B) MONITOR DISPLAY IS NORMAL BUT BUZZER SOUNDS..................................................................................437 M-8 ABNORMALITY IN WARNING LAMP.....................................................................................................438 A) CAUTION ITEM FLASHES BUT WARNING LAMP DOES NOT FLASH, OR WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), WARNING LAM....438 B) MONITOR DISPLAY IS NORMAL BUT WARNING LAMP LIGHTS UP.........................................................................438 M-9 ABNORMALITY IN GAUGE............................................................................................................439 A) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE..............................................................................439 B) ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE..........................................................439 C) ABNORMALITY IN FUEL LEVEL GAUGE..............................................................................................440 M-10 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED............................................................................441 M-11 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMP, WORKING LAMP ARE NORMAL).................................................442 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................................................................443 ELECTRICAL CIRCUIT DRAWING FOR E MODE SYSTEM.........................................................................................444 E-1 ENGINE DOES NOT START...........................................................................................................447 E-2 DEFECTIVE OPERATION OF APS......................................................................................................449 A) PREHEATING MONITOR LAMP DOES NOT LIGHT UP DURING PREHEATING..................................................................449 B) PREHEATING MONITOR LAMP STAYS LIGHTED UP AFTER PREHEATING IS COMPLETED.......................................................449 C) PREHEATING MONITOR LAMP FLASHES AFTER PREHEATING IS COMPLETED................................................................450 D) PREHEATING MONITOR LAMP LIGHTS UP WHEN ENGINE IS STARTED (STARTING SWITCH AT START) AFTER PREHEATING IS COMPLETED............450 E) APS IS NOT ACTUATED WHEN WATER TEMPERATURE IS BELOW 20C......................................................................451 F) APS IS ACTUATED WHEN WATER TEMPERATURE IS ABOVE 20C..........................................................................453 G) APS IS ACTUATED WHEN WATER TEMPERATURE IS BELOW 20C BUT APS SWITCH IS NOT TURNED ON..........................................453 E-3 DEFECTIVE OPERATION OF BACK-UP ALARM............................................................................................454 A) BACK-UP ALARM DOES NOT SOUND.................................................................................................454 B) BACK-UP ALARM DOES NOT STOP SOUNDING.........................................................................................454 E-4 LAMP DO NOT LIGHT UP............................................................................................................455 A) FRONT LAMPS..................................................................................................................455 B) WORKING LAMPS................................................................................................................455 C) REAR LAMPS (RIPPER LAMP).....................................................................................................457 E-5 PIN-PULLER CYLINDER DOES NOT WORK (ONLY MACHINES EQUIPPED WITH GIANT RIPPER)....................................................458 E-6 BLADE DUAL TILT DOES NOT WORK (DUAL TILTDOZER SPECIFICATION)....................................................................459 E-7 BLADE PITCH DOES NOT WORK (DUAL TILTDOZER SPECIFICATION)........................................................................460 TROUBLESHOOTING OF AIR CONDITIONER SYSTEM................................................................................................462 ELECTRICAL CIRCUIT DIAGRAM OF AIR CONDITONER SYSTEM..................................................................................463 TROUBLESHOOTING OF AIR CONDITIONER WHICH DOES NOT WORK...............................................................................464 30 DISASSEMBLY AND ASSEMBLY.....................................................................................................................470 METHOD OF USING MANUAL.......................................................................................................................473 PRECAUTIONS WHEN CARRYING OUT OPERATION......................................................................................................475 SPECIAL TOOL LIST............................................................................................................................477 SKETCHES OF SPECIAL TOOLS....................................................................................................................486 STARTING MOTOR...............................................................................................................................491 REMOVAL..................................................................................................................................491 INSTALLATION.............................................................................................................................491 ALTERNATOR...................................................................................................................................492 REMOVAL..................................................................................................................................492 INSTALLATION.............................................................................................................................492 ENGINE OIL COOLER............................................................................................................................493 REMOVAL..................................................................................................................................493 INSTALLATION.............................................................................................................................494 FUEL INJECTION PUMP..........................................................................................................................495 REMOVAL..................................................................................................................................495 INSTALLATION.............................................................................................................................495 WATER PUMP...................................................................................................................................496 REMOVAL..................................................................................................................................496 INSTALLATION.............................................................................................................................496 THERMOSTAT...................................................................................................................................497 REMOVAL..................................................................................................................................497 INSTALLATION.............................................................................................................................497 TURBOCHARGER.................................................................................................................................498 REMOVAL..................................................................................................................................498 INSTALLATION.............................................................................................................................499 AFTERCOOLER CORE.............................................................................................................................500 REMOVAL..................................................................................................................................500 INSTALLATION.............................................................................................................................501 NOZZLE HOLDER................................................................................................................................502 REMOVAL..................................................................................................................................502 INSTALLATION.............................................................................................................................502 ENGINE FRONT SEAL............................................................................................................................503 REMOVAL..................................................................................................................................503 INSTALLATION.............................................................................................................................503 ENGINE REAR SEAL.............................................................................................................................505 REMOVAL..................................................................................................................................505 INSTALLATION.............................................................................................................................505 CYLINDER HEAD................................................................................................................................507 REMOVAL..................................................................................................................................507 INSTALLATION.............................................................................................................................512 IN-LINE SERVO VALVE..........................................................................................................................514 REMOVAL..................................................................................................................................514 INSTALLATION.............................................................................................................................514 DISASSEMBLY..............................................................................................................................515 ASSEMBLY.................................................................................................................................516 SHOE SLIP CONTROLLER.........................................................................................................................517 REMOVAL..................................................................................................................................517 INSTALLATION.............................................................................................................................517 ELECTRIC ENGINE THROTTLE CONTROLLER .........................................................................................................518 REMOVAL..................................................................................................................................518 INSTALLATION.............................................................................................................................518 FUEL TANK....................................................................................................................................519 REMOVAL..................................................................................................................................519 INSTALLATION.............................................................................................................................519 RADIATOR.....................................................................................................................................520 REMOVAL..................................................................................................................................520 INSTALLATION.............................................................................................................................521 RADIATOR GUARD...............................................................................................................................522 REMOVAL..................................................................................................................................522 INSTALLATION.............................................................................................................................524 ENGINE.......................................................................................................................................525 REMOVAL..................................................................................................................................525 INSTALLATION.............................................................................................................................530 DAMPER.......................................................................................................................................531 REMOVAL..................................................................................................................................531 INSTALLATION.............................................................................................................................534 DISASSEMBLY..............................................................................................................................536 ASSEMBLY.................................................................................................................................537 POWER TRAIN UNIT.............................................................................................................................539 REMOVAL..................................................................................................................................539 INSTALLATION.............................................................................................................................543 DISCONNECTION............................................................................................................................544 CONNECTION...............................................................................................................................550 PTO..........................................................................................................................................552 DISASSEMBLY..............................................................................................................................552 ASSEMBLY.................................................................................................................................556 TORQUE CONVERTER.............................................................................................................................560 DISASSEMBLY..............................................................................................................................560 ASSEMBLY.................................................................................................................................565 TORQFLOW TRANSMISSION........................................................................................................................571 DISASSEMBLY..............................................................................................................................571 ASSEMBLY.................................................................................................................................587 STEERING CASE................................................................................................................................604 DISASSEMBLY..............................................................................................................................604 ASSEMBLY.................................................................................................................................612 POWER TRAIN, LUBRICATION PUMP................................................................................................................622 REMOVAL..................................................................................................................................622 INSTALLATION.............................................................................................................................622 SCAVENGING PUMP..............................................................................................................................623 REMOVAL..................................................................................................................................623 INSTALLATION ............................................................................................................................623 TORQUE CONVERTER OIL COOLER..................................................................................................................624 REMOVAL..................................................................................................................................624 INSTALLATION.............................................................................................................................624 TORQUE CONVERTER VALVE.......................................................................................................................625 REMOVAL..................................................................................................................................625 INSTALLATION.............................................................................................................................626 DISASSEMBLY..............................................................................................................................627 ASSEMBLY.................................................................................................................................629 TRANSMISSION CONTROL VALVE...................................................................................................................630 REMOVAL..................................................................................................................................630 INSTALLATION.............................................................................................................................631 DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY.......................................................................................632 ASSEMBLY.................................................................................................................................633 TRANSMISSION LUBRICATION VALVE...............................................................................................................634 REMOVAL..................................................................................................................................634 INSTALLATION ............................................................................................................................634 DISASSEMBLY..............................................................................................................................635 ASSEMBLY.................................................................................................................................635 STEERING CONTROL VALVE.......................................................................................................................636 REMOVAL..................................................................................................................................636 INSTALLATION.............................................................................................................................636 DISASSEMBLY..............................................................................................................................637 ASSEMBLY.................................................................................................................................639 FINAL DRIVE..................................................................................................................................641 REMOVAL..................................................................................................................................641 INSTALLATION.............................................................................................................................641 DISASSEMBLY..............................................................................................................................642 ASSEMBLY.................................................................................................................................648 TRACK FRAME..................................................................................................................................657 REMOVAL..................................................................................................................................657 INSTALLATION.............................................................................................................................659 IDLER........................................................................................................................................660 REMOVAL..................................................................................................................................660 INSTALLATION.............................................................................................................................660 DISASSEMBLY..............................................................................................................................661 ASSEMBLY.................................................................................................................................663 RECOIL SPRING................................................................................................................................665 REMOVAL..................................................................................................................................665 INSTALLATION.............................................................................................................................670 DISASSEMBLY..............................................................................................................................671 ASSEMBLY.................................................................................................................................672 TRACK ROLLER.................................................................................................................................673 REMOVAL..................................................................................................................................673 INSTALLATION.............................................................................................................................674 DISASSEMBLY..............................................................................................................................675 ASSEMBLY.................................................................................................................................676 BOGIE .......................................................................................................................................678 REMOVAL..................................................................................................................................678 INSTALLATION.............................................................................................................................679 DISASSEMBLY..............................................................................................................................680 ASSEMBLY.................................................................................................................................684 FIRST BOGIE..................................................................................................................................689 REMOVAL..................................................................................................................................689 INSTALLATION.............................................................................................................................692 CARRIER ROLLER...............................................................................................................................695 REMOVAL..................................................................................................................................695 INSTALLATION.............................................................................................................................695 DISASSEMBLY..............................................................................................................................696 ASSEMBLY.................................................................................................................................698 TRACK SHOE ..................................................................................................................................701 REMOVAL..................................................................................................................................701 INSTALLATION.............................................................................................................................703 OVERALL DISASSEMBLY OF TRACK SHOE............................................................................................................704 OVERALL ASSEMBLY.............................................................................................................................709 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.............................................................................................723 ONE LINK.....................................................................................................................................724 FIELD DISASSEMBLY........................................................................................................................724 FIELD ASSEMBLY...........................................................................................................................726 MASTER LINK..................................................................................................................................728 FIELD DISASSEMBLY........................................................................................................................728 FIELD ASSEMBLY...........................................................................................................................730 PIVOT SHAFT..................................................................................................................................733 REMOVAL..................................................................................................................................733 INSTALLATION.............................................................................................................................733 EQUALIZER BAR................................................................................................................................734 REMOVAL..................................................................................................................................734 INSTALLATION.............................................................................................................................737 EQUALIZER BAR BUSHING........................................................................................................................738 DISASSEMBLY..............................................................................................................................738 ASSEMBLY.................................................................................................................................739 SEGMENT TOOTH................................................................................................................................740 REMOVAL..................................................................................................................................740 INSTALLATION.............................................................................................................................740 HYDRAULIC TANK...............................................................................................................................741 ASSEMBLY.................................................................................................................................741 INSTALLATION.............................................................................................................................743 WORK EQUIPMENT, PPC PUMP ....................................................................................................................744 REMOVAL..................................................................................................................................744 INSTALLATION.............................................................................................................................744 HYDRAULIC COOLER.............................................................................................................................745 REMOVAL..................................................................................................................................745 INSTALLATION.............................................................................................................................745 BLADE LIFT VALVE.............................................................................................................................746 REMOVAL..................................................................................................................................746 INSTALLATION.............................................................................................................................747 DISASSEMBLY..............................................................................................................................748 ASSEMBLY.................................................................................................................................749 BLADE TILT, RIPPLER LO VALVE.................................................................................................................750 REMOVAL..................................................................................................................................750 INSTALLATION.............................................................................................................................751 DISASSEMBLY..............................................................................................................................752 ASSEMBLY.................................................................................................................................753 RIPPER HI VALVE..............................................................................................................................754 REMOVAL..................................................................................................................................754 INSTALLATION.............................................................................................................................754 DISASSEMBLY..............................................................................................................................755 ASSEMBLY.................................................................................................................................756 PPC CHARGE VALVE.............................................................................................................................757 REMOVAL..................................................................................................................................757 INSTALLATION.............................................................................................................................757 DISASSEMBLY..............................................................................................................................758 ASSEMBLY.................................................................................................................................758 BLADE PPC VALVE .............................................................................................................................759 REMOVAL..................................................................................................................................759 INSTALLATION.............................................................................................................................760 DISASSEMBLY..............................................................................................................................761 ASSEMBLY.................................................................................................................................762 RIPPER PPC VALVE.............................................................................................................................764 REMOVAL..................................................................................................................................764 INSTALLATION.............................................................................................................................765 DISASSEMBLY..............................................................................................................................766 ASSEMBLY.................................................................................................................................767 BLADE LIFT CYLINDER..........................................................................................................................768 REMOVAL..................................................................................................................................768 INSTALLATION.............................................................................................................................768 BLADE TILT CYLINDER..........................................................................................................................769 REMOVAL..................................................................................................................................769 INSTALLATION.............................................................................................................................769 RIPPER LIFT CYLINDER ........................................................................................................................770 REMOVAL..................................................................................................................................770 INSTALLATION.............................................................................................................................770 RIPPER TILT CYLINDER.........................................................................................................................771 REMOVAL..................................................................................................................................771 INSTALLATION.............................................................................................................................771 HYDRAULIC CYLINDER...........................................................................................................................772 DISASSEMBLY..............................................................................................................................772 ASSEMBLY.................................................................................................................................775 RIPPER PIN-PULLER CYLINDER...................................................................................................................778 REMOVAL..................................................................................................................................778 INSTALLATION.............................................................................................................................778 DISASSEMBLY..............................................................................................................................779 ASSEMBLY.................................................................................................................................780 BLADE........................................................................................................................................782 REMOVAL..................................................................................................................................782 INSTALLATION.............................................................................................................................783 DISASSEMBLY..............................................................................................................................784 ASSEMBLY.................................................................................................................................786 GIANT RIPPER.................................................................................................................................788 DISASSEMBLY..............................................................................................................................788 ASSEMBLY.................................................................................................................................790 ROPS GUARD...................................................................................................................................792 REMOVAL..................................................................................................................................792 INSTALLATION.............................................................................................................................792 OPERATOR'S CAB ..............................................................................................................................793 REMOVAL..................................................................................................................................793 INSTALLATION.............................................................................................................................794 FLOOR FRAME..................................................................................................................................795 REMOVAL..................................................................................................................................795 INSTALLATION.............................................................................................................................799 DASHBOARD....................................................................................................................................801 REMOVAL..................................................................................................................................801 INSTALLATION.............................................................................................................................802 MONITOR PANEL................................................................................................................................803 REMOVAL..................................................................................................................................803 INSTALLATION.............................................................................................................................803 TORQUE CONVERTER LOCK-UP CONTROLLER..........................................................................................................804 REMOVAL..................................................................................................................................804 INSTALLATION.............................................................................................................................804 APS CONTROLLER...............................................................................................................................805 REMOVAL..................................................................................................................................805 INSTALLATION.............................................................................................................................805 AIR CONDITIONER COMPRESSOR...................................................................................................................806 REMOVAL..................................................................................................................................806 INSTALLATION.............................................................................................................................807 AIR CONDITIONER CONDENSER....................................................................................................................808 REMOVAL..................................................................................................................................808 INSTALLATION.............................................................................................................................808 AIR CONDITIONER UNIT.........................................................................................................................809 REMOVAL..................................................................................................................................809 INSTALLATION.............................................................................................................................812 HOOD.........................................................................................................................................813 REMOVAL..................................................................................................................................813 INSTALLATION.............................................................................................................................813 40 MAINTENANCE STANDARD.........................................................................................................................814 ENGINE MOUNT.................................................................................................................................815 DAMPER, UNIVERSAL JOINT......................................................................................................................816 TORQUE CONVERTER.............................................................................................................................817 TORQUE CONVERTER VALVE.......................................................................................................................819 TRANSMISSION.................................................................................................................................821 TRANSMISSION CONTROL VALVE...................................................................................................................823 POWER TRAIN LUBRICATION + POWER TRAIN PUMP...................................................................................................825 SCAVENGING PUMP..............................................................................................................................826 TRANSFER, BEVEL PINION.......................................................................................................................827 BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE.....................................................................................................828 STEERING CONTROL VALVE.......................................................................................................................830 FINAL DRIVE..................................................................................................................................832 MAIN FRAME...................................................................................................................................834 TRACK FRAME..................................................................................................................................836 RECOIL SPRING................................................................................................................................837 IDLER........................................................................................................................................838 TRACK ROLLER BOGIE...........................................................................................................................840 TRACK ROLLER.................................................................................................................................842 CARRIER ROLLER...............................................................................................................................844 TRACK SHOE...................................................................................................................................846 SINGLE SHOE..................................................................................................................................849 EQUALIZER BAR................................................................................................................................850 PIVOT SHAFT..................................................................................................................................852 WORK EQUIPMENT + PPC CHARGE PUMP.............................................................................................................854 WORK EQUIPMENT CONTROL VALVE.................................................................................................................856 PPC VALVE....................................................................................................................................860 PPC CHARGE VALVE.............................................................................................................................863 WORK EQUIPMENT CYLINDER......................................................................................................................864 QUICK DROP VALVE.............................................................................................................................868 CYLINDER STAY................................................................................................................................869 BLADE........................................................................................................................................870 RIPPER EQUIPMENT.............................................................................................................................875 90 OTHERS.......................................................................................................................................879 ELECTRIC CIRCUIT DIAGRAM.....................................................................................................................880 CHASSIS ELECTRIC CIRCUIT DIAGRAM (1/2)...................................................................................................880 CHASSIS ELECTRIC CIRCUIT DIAGRAM (2/2)...................................................................................................885 ELECTRIC CIRCUIT DIAGRAM INSIDE CAB......................................................................................................890
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