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Description
KOMATSU D375A-3 SHOP MANUAL SEBM016103 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D375A-3 SHOP MANUAL SEBM016103 – PDF DOWNLOAD
Language : English
Pages : 883
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D375A-3 SHOP MANUAL SEBM016103 – PDF DOWNLOAD
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 30 DISASSEMBLY AND ASSEMBLY.....................................................................................................................462 METHOD OF USING MANUAL.......................................................................................................................465 PRECAUTIONS WHEN CARRYING OUT OPERATION......................................................................................................467 SPECIAL TOOL LIST............................................................................................................................469 SKETCHES OF SPECIAL TOOLS....................................................................................................................478 STARTING MOTOR...............................................................................................................................483 REMOVAL..................................................................................................................................483 INSTALLATION.............................................................................................................................483 ALTERNATOR...................................................................................................................................484 REMOVAL..................................................................................................................................484 INSTALLATION.............................................................................................................................484 ENGINE OIL COOLER............................................................................................................................485 REMOVAL..................................................................................................................................485 INSTALLATION.............................................................................................................................486 FUEL INJECTION PUMP..........................................................................................................................487 REMOVAL..................................................................................................................................487 INSTALLATION.............................................................................................................................487 WATER PUMP...................................................................................................................................488 REMOVAL..................................................................................................................................488 INSTALLATION.............................................................................................................................488 THERMOSTAT...................................................................................................................................489 REMOVAL..................................................................................................................................489 INSTALLATION.............................................................................................................................489 TURBOCHARGER.................................................................................................................................490 REMOVAL..................................................................................................................................490 INSTALLATION.............................................................................................................................491 AFTERCOOLER CORE.............................................................................................................................492 REMOVAL..................................................................................................................................492 INSTALLATION.............................................................................................................................493 NOZZLE HOLDER................................................................................................................................494 REMOVAL..................................................................................................................................494 INSTALLATION.............................................................................................................................494 ENGINE FRONT SEAL............................................................................................................................495 REMOVAL..................................................................................................................................495 INSTALLATION.............................................................................................................................495 ENGINE REAR SEAL.............................................................................................................................497 REMOVAL..................................................................................................................................497 INSTALLATION.............................................................................................................................497 CYLINDER HEAD................................................................................................................................499 REMOVAL..................................................................................................................................499 INSTALLATION.............................................................................................................................504 IN-LINE SERVO VALVE..........................................................................................................................506 REMOVAL..................................................................................................................................506 INSTALLATION.............................................................................................................................506 DISASSEMBLY..............................................................................................................................507 ASSEMBLY.................................................................................................................................508 SHOE SLIP CONTROLLER.........................................................................................................................509 REMOVAL..................................................................................................................................509 INSTALLATION.............................................................................................................................509 ELECTRIC ENGINE THROTTLE CONTROLLER .........................................................................................................510 REMOVAL..................................................................................................................................510 INSTALLATION.............................................................................................................................510 FUEL TANK....................................................................................................................................511 REMOVAL..................................................................................................................................511 INSTALLATION.............................................................................................................................511 RADIATOR.....................................................................................................................................512 REMOVAL..................................................................................................................................512 INSTALLATION.............................................................................................................................513 RADIATOR GUARD...............................................................................................................................514 REMOVAL..................................................................................................................................514 INSTALLATION.............................................................................................................................516 ENGINE.......................................................................................................................................517 REMOVAL..................................................................................................................................517 INSTALLATION.............................................................................................................................522 DAMPER.......................................................................................................................................523 REMOVAL..................................................................................................................................523 INSTALLATION.............................................................................................................................526 DISASSEMBLY..............................................................................................................................528 ASSEMBLY.................................................................................................................................529 POWER TRAIN UNIT.............................................................................................................................531 REMOVAL..................................................................................................................................531 INSTALLATION.............................................................................................................................535 DISCONNECTION............................................................................................................................536 CONNECTION...............................................................................................................................542 PTO..........................................................................................................................................544 DISASSEMBLY..............................................................................................................................544 ASSEMBLY.................................................................................................................................548 TORQUE CONVERTER.............................................................................................................................552 DISASSEMBLY..............................................................................................................................552 ASSEMBLY.................................................................................................................................557 TORQFLOW TRANSMISSION........................................................................................................................563 DISASSEMBLY..............................................................................................................................563 ASSEMBLY.................................................................................................................................579 STEERING CASE................................................................................................................................596 DISASSEMBLY..............................................................................................................................596 ASSEMBLY.................................................................................................................................604 POWER TRAIN, LUBRICATION PUMP................................................................................................................614 REMOVAL..................................................................................................................................614 INSTALLATION.............................................................................................................................614 SCAVENGING PUMP..............................................................................................................................615 REMOVAL..................................................................................................................................615 INSTALLATION ............................................................................................................................615 TORQUE CONVERTER OIL COOLER..................................................................................................................616 REMOVAL..................................................................................................................................616 INSTALLATION.............................................................................................................................616 TORQUE CONVERTER VALVE.......................................................................................................................617 REMOVAL..................................................................................................................................617 INSTALLATION.............................................................................................................................618 DISASSEMBLY..............................................................................................................................619 ASSEMBLY.................................................................................................................................621 TRANSMISSION CONTROL VALVE...................................................................................................................622 REMOVAL..................................................................................................................................622 INSTALLATION.............................................................................................................................623 DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY.......................................................................................624 ASSEMBLY.................................................................................................................................625 TRANSMISSION LUBRICATION VALVE...............................................................................................................626 REMOVAL..................................................................................................................................626 INSTALLATION ............................................................................................................................626 DISASSEMBLY..............................................................................................................................627 ASSEMBLY.................................................................................................................................627 STEERING CONTROL VALVE.......................................................................................................................628 REMOVAL..................................................................................................................................628 INSTALLATION.............................................................................................................................628 DISASSEMBLY..............................................................................................................................629 ASSEMBLY.................................................................................................................................631 FINAL DRIVE..................................................................................................................................633 REMOVAL..................................................................................................................................633 INSTALLATION.............................................................................................................................633 DISASSEMBLY..............................................................................................................................634 ASSEMBLY.................................................................................................................................640 TRACK FRAME..................................................................................................................................649 REMOVAL..................................................................................................................................649 INSTALLATION.............................................................................................................................651 IDLER........................................................................................................................................652 REMOVAL..................................................................................................................................652 INSTALLATION.............................................................................................................................652 DISASSEMBLY..............................................................................................................................653 ASSEMBLY.................................................................................................................................655 RECOIL SPRING................................................................................................................................657 REMOVAL..................................................................................................................................657 INSTALLATION.............................................................................................................................662 DISASSEMBLY..............................................................................................................................663 ASSEMBLY.................................................................................................................................664 TRACK ROLLER.................................................................................................................................665 REMOVAL..................................................................................................................................665 INSTALLATION.............................................................................................................................666 DISASSEMBLY..............................................................................................................................667 ASSEMBLY.................................................................................................................................668 BOGIE .......................................................................................................................................670 REMOVAL..................................................................................................................................670 INSTALLATION.............................................................................................................................671 DISASSEMBLY..............................................................................................................................672 ASSEMBLY.................................................................................................................................676 FIRST BOGIE..................................................................................................................................681 REMOVAL..................................................................................................................................681 INSTALLATION.............................................................................................................................684 CARRIER ROLLER...............................................................................................................................687 REMOVAL..................................................................................................................................687 INSTALLATION.............................................................................................................................687 DISASSEMBLY..............................................................................................................................688 ASSEMBLY.................................................................................................................................690 TRACK SHOE ..................................................................................................................................693 REMOVAL..................................................................................................................................693 INSTALLATION.............................................................................................................................695 OVERALL DISASSEMBLY OF TRACK SHOE............................................................................................................696 OVERALL ASSEMBLY.............................................................................................................................701 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.............................................................................................715 ONE LINK.....................................................................................................................................716 FIELD DISASSEMBLY........................................................................................................................716 FIELD ASSEMBLY...........................................................................................................................718 MASTER LINK..................................................................................................................................720 FIELD DISASSEMBLY........................................................................................................................720 FIELD ASSEMBLY...........................................................................................................................722 PIVOT SHAFT..................................................................................................................................725 REMOVAL..................................................................................................................................725 INSTALLATION.............................................................................................................................725 EQUALIZER BAR................................................................................................................................726 REMOVAL..................................................................................................................................726 INSTALLATION.............................................................................................................................729 EQUALIZER BAR BUSHING........................................................................................................................730 DISASSEMBLY..............................................................................................................................730 ASSEMBLY.................................................................................................................................731 SEGMENT TOOTH................................................................................................................................732 REMOVAL..................................................................................................................................732 INSTALLATION.............................................................................................................................732 HYDRAULIC TANK...............................................................................................................................733 ASSEMBLY.................................................................................................................................733 INSTALLATION.............................................................................................................................735 WORK EQUIPMENT, PPC PUMP ....................................................................................................................736 REMOVAL..................................................................................................................................736 INSTALLATION.............................................................................................................................736 HYDRAULIC COOLER.............................................................................................................................737 REMOVAL..................................................................................................................................737 INSTALLATION.............................................................................................................................737 BLADE LIFT VALVE.............................................................................................................................738 REMOVAL..................................................................................................................................738 INSTALLATION.............................................................................................................................739 DISASSEMBLY..............................................................................................................................740 ASSEMBLY.................................................................................................................................741 BLADE TILT, RIPPLER LO VALVE.................................................................................................................742 REMOVAL..................................................................................................................................742 INSTALLATION.............................................................................................................................743 DISASSEMBLY..............................................................................................................................744 ASSEMBLY.................................................................................................................................745 RIPPER HI VALVE..............................................................................................................................746 REMOVAL..................................................................................................................................746 INSTALLATION.............................................................................................................................746 DISASSEMBLY..............................................................................................................................747 ASSEMBLY.................................................................................................................................748 PPC CHARGE VALVE.............................................................................................................................749 REMOVAL..................................................................................................................................749 INSTALLATION.............................................................................................................................749 DISASSEMBLY..............................................................................................................................750 ASSEMBLY.................................................................................................................................750 BLADE PPC VALVE .............................................................................................................................751 REMOVAL..................................................................................................................................751 INSTALLATION.............................................................................................................................752 DISASSEMBLY..............................................................................................................................753 ASSEMBLY.................................................................................................................................754 RIPPER PPC VALVE.............................................................................................................................756 REMOVAL..................................................................................................................................756 INSTALLATION.............................................................................................................................757 DISASSEMBLY..............................................................................................................................758 ASSEMBLY.................................................................................................................................759 BLADE LIFT CYLINDER..........................................................................................................................760 REMOVAL..................................................................................................................................760 INSTALLATION.............................................................................................................................760 BLADE TILT CYLINDER..........................................................................................................................761 REMOVAL..................................................................................................................................761 INSTALLATION.............................................................................................................................761 RIPPER LIFT CYLINDER ........................................................................................................................762 REMOVAL..................................................................................................................................762 INSTALLATION.............................................................................................................................762 RIPPER TILT CYLINDER.........................................................................................................................763 REMOVAL..................................................................................................................................763 INSTALLATION.............................................................................................................................763 HYDRAULIC CYLINDER...........................................................................................................................764 DISASSEMBLY..............................................................................................................................764 ASSEMBLY.................................................................................................................................767 RIPPER PIN-PULLER CYLINDER...................................................................................................................770 REMOVAL..................................................................................................................................770 INSTALLATION.............................................................................................................................770 DISASSEMBLY..............................................................................................................................771 ASSEMBLY.................................................................................................................................772 BLADE........................................................................................................................................774 REMOVAL..................................................................................................................................774 INSTALLATION.............................................................................................................................775 DISASSEMBLY..............................................................................................................................776 ASSEMBLY.................................................................................................................................778 GIANT RIPPER.................................................................................................................................780 DISASSEMBLY..............................................................................................................................780 ASSEMBLY.................................................................................................................................782 ROPS GUARD...................................................................................................................................784 REMOVAL..................................................................................................................................784 INSTALLATION.............................................................................................................................784 OPERATOR'S CAB ..............................................................................................................................785 REMOVAL..................................................................................................................................785 INSTALLATION.............................................................................................................................786 FLOOR FRAME..................................................................................................................................787 REMOVAL..................................................................................................................................787 INSTALLATION.............................................................................................................................791 DASHBOARD....................................................................................................................................793 REMOVAL..................................................................................................................................793 INSTALLATION.............................................................................................................................794 MONITOR PANEL................................................................................................................................795 REMOVAL..................................................................................................................................795 INSTALLATION.............................................................................................................................795 TORQUE CONVERTER LOCK-UP CONTROLLER..........................................................................................................796 REMOVAL..................................................................................................................................796 INSTALLATION.............................................................................................................................796 APS CONTROLLER...............................................................................................................................797 REMOVAL..................................................................................................................................797 INSTALLATION.............................................................................................................................797 AIR CONDITIONER COMPRESSOR...................................................................................................................798 REMOVAL..................................................................................................................................798 INSTALLATION.............................................................................................................................799 AIR CONDITIONER CONDENSER....................................................................................................................800 REMOVAL..................................................................................................................................800 INSTALLATION.............................................................................................................................800 AIR CONDITIONER UNIT.........................................................................................................................801 REMOVAL..................................................................................................................................801 INSTALLATION.............................................................................................................................804 HOOD.........................................................................................................................................805 REMOVAL..................................................................................................................................805 INSTALLATION.............................................................................................................................805 40 MAINTENANCE STANDARD.........................................................................................................................806 ENGINE MOUNT.................................................................................................................................807 DAMPER, UNIVERSAL JOINT......................................................................................................................808 TORQUE CONVERTER.............................................................................................................................809 TORQUE CONVERTER VALVE.......................................................................................................................811 TRANSMISSION.................................................................................................................................813 TRANSMISSION CONTROL VALVE...................................................................................................................815 POWER TRAIN LUBRICATION + POWER TRAIN PUMP...................................................................................................817 SCAVENGING PUMP..............................................................................................................................818 TRANSFER, BEVEL PINION.......................................................................................................................819 BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE.....................................................................................................820 STEERING CONTROL VALVE.......................................................................................................................822 FINAL DRIVE..................................................................................................................................824 MAIN FRAME...................................................................................................................................826 TRACK FRAME..................................................................................................................................828 RECOIL SPRING................................................................................................................................829 IDLER........................................................................................................................................830 TRACK ROLLER BOGIE...........................................................................................................................832 TRACK ROLLER.................................................................................................................................834 CARRIER ROLLER...............................................................................................................................836 TRACK SHOE...................................................................................................................................838 SINGLE SHOE..................................................................................................................................841 EQUALIZER BAR................................................................................................................................842 PIVOT SHAFT..................................................................................................................................844 WORK EQUIPMENT + PPC CHARGE PUMP.............................................................................................................846 WORK EQUIPMENT CONTROL VALVE.................................................................................................................848 PPC VALVE....................................................................................................................................852 PPC CHARGE VALVE.............................................................................................................................855 WORK EQUIPMENT CYLINDER......................................................................................................................856 QUICK DROP VALVE.............................................................................................................................860 CYLINDER STAY................................................................................................................................861 BLADE........................................................................................................................................862 RIPPER EQUIPMENT.............................................................................................................................867 90 OTHERS.......................................................................................................................................871 ELECTRIC CIRCUIT DIAGRAM.....................................................................................................................872 CHASSIS ELECTRIC CIRCUIT DIAGRAM (1/2)...................................................................................................872 CHASSIS ELECTRIC CIRCUIT DIAGRAM (2/2)...................................................................................................877 ELECTRIC CIRCUIT DIAGRAM INSIDE CAB......................................................................................................882
DESCRIPTION:
KOMATSU D375A-3 SHOP MANUAL SEBM016103 – PDF DOWNLOAD
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
S.S 26/12/24
