Komatsu D375A-5 Crawler Bulldozer Shop Manual SEBM035200 PDF DOWNLOAD

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Komatsu D375A-5 Crawler Bulldozer Shop Manual SEBM035200  – PDF DOWNLOAD

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Komatsu D375A-5 Crawler Bulldozer Shop Manual SEBM035200  – PDF DOWNLOAD

Language : English
Pages : 693
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D375A-5 Crawler Bulldozer Shop Manual SEBM035200  – PDF DOWNLOAD

• MACHINE MODEL         SERIAL NUMBER
  D375A-5                          18200 and up

COVER 1
CONTENTS . 2
01 GENERAL . 23
SPECIFICATION DRAWINGS . 24
SPECIFICATIONS . 25
WEIGHT TABLE . 30
TABLE OF FUEL, COOLANT AND LUBRICANTS 32
10 STRUCTURE AND FUNCTION 34
ENGINE CONTROL . 35
POWER TRAIN 36
OVERALL DRAWING OF POWER TRAIN UNIT 38
POWER TRAIN HYDRAULIC PIPING DIAGRAM . 40
POWER TRAIN HYDRAULIC CIRCUIT DRAWING 41
DAMPER, UNIVERSAL JOINT 43
TORQUE CONVERTER, PTO 45
TORQUE CONVERTER VALVE . 50
TRANSMISSION CONTROL . 52
TRANSMISSION . 53
TRANSMISSION CONTROL VALVE . 60
TRANSMISSION LUBRICATION RELIEF VALVE 67
SCAVENGING PUMP STRAINER . 68
OVERFLOW VALVE . 69
POWER TRAIN PUMP STRAINER 71
POWER TRAIN, LUBRICATING OIL FILTER 72
STEERING, BRAKE CONTROL 73
TRANSFER, BEVEL GEAR SHAFT, STEERING . 77
STEERING CONTROL VALVE . 81
FINAL DRIVE 89
TRACK FRAME 93
RECOIL SPRING 95
TRACK ROLLER BOGIE . 97
MAIN FRAME . 98
SUSPENSION . 99
PPC CONTROL PIPING DIAGRAM .101
WORK EQUIPMENT CONTROL .102
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM .104
HYDRAULIC TANK .106
PPC CHARGE VALVE .107
ACCUMULATOR 109
PPC LOCK VALVE .110
PISTON VALVE .121
QUICK DROP VALVE .122
PIN PULLER SWITCH 123
PIN PULLER SOLENOID VALVE 124
BLADE CONTROL KNOB .126
MAIN CONTROL VALVE .127
CYLINDER STAY 153
BLADE 154
RIPPER .156
CAB MOUNT 158
CAB 159
AIR CONDITIONER 160
MONITOR SYSTEM .161
SWITCH PANEL .169
FUSE BOX .169
ENGINE START SAFETY SYSTEM .171
APS 172
20 TESTING AND ADJUSTING .174
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 175
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS .176
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS 181
STANDARD VALUE TABLE FOR MONITOR .182
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING .183
MEASURING ENGINE SPEED .184
MEASURING EXHAUST COLOR 185
ADJUSTING VALVE CLEARANCE 186
MEASURING COMPRESSION PRESSURE .187
MEASURING BLOW-BY PRESSURE .188
MEASURING ENGINE OIL PRESSURE 189
TESTING AND ADJUSTING FUEL INJECTION TIMING .190
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 192
TESTING AND ADJUSTING BELT TENSION FOR AIR CONDITIONER COMPRESSOR 192
MEASURING EXHAUST TEMPERATURE 193
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) .194
MEASURING TORQUE CONVERTER STALL SPEED .195
MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL) 196
ADJUSTING FUEL CONTROL LINKAGE .197
ADJUSTING DECELERATOR PEDAL 200
ADJUSTING JOYSTICK (STEERING, DIRECTIONAL, SPEED CONTROL LEVER), PARKING BRAKE LEVEL LINKAGE .201
ADJUSTING BRAKE PEDAL LINKAGE 205
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE .206
MEASURING POWER TRAIN OIL PRESSURE .207
MEASURING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 210
TESTING AND ADJUSTING WORK EQUIPMENT CONTROL CIRCUIT PRESSURE 212
MEASURING PPC VALVE OUTPUT PRESSURE 213
ADJUSTING PPC VALVE 214
MEASURING ON-OFF SOLENOID VALVE OUTPUT PRESSURE 215
BLEEDING AIR FROM HYDRAULIC CYLINDERS 216
RELEASING REMAINING PRESSURE IN HYDRAULIC CIRCUIT 216
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER 217
MEASURING LEAKAGE INSIDE HYDRAULIC CYLINDER 218
ADJUSTING SEMI U-TILTDOZER .219
ADJUSTING IDLER CLEARANCE 221
SIMPLE PROCEDURE FOR TESTING BRAKE PERFORMANCE .221
TROUBLESHOOTING 222
POINTS TO REMEMBER WHEN TROUBLESHOOTING .223
SEQUENCE OF EVENTS IN TROUBLESHOOTING 224
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE .225
CHECKS BEFORE TROUBLESHOOTING 233
TYPE OF CONNECTOR AND POSITION OF INSTALLATION .234
CONNECTOR ARRANGEMENT DIAGRAM 236
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS .241
METHOD OF USING TROUBLESHOOTING CHARTS .251
TROUBLESHOOTING OF ENGING SYSTEM (S MODE) 253
METHOD OF USING TROUBLESHOOTING CHARTS .254
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 258
S-2 ENGINE DOES NOT START 259
1) ENGINE DOES NOT TURN 259
2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS BEING INJECTED) 260
3) EXHAUST SMOKE COMES OUT BUT ENGINE DOS NOT START (FUEL IS BEING INJECTED) .261
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) .262
S-4 ENGINE STOPS DURING OPERATIONS .263
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 264
S-6 ENGINE LACKS OUTPUT (NO POWER) .265
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION) .266
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE) 267
S-9 OIL BECOMES CONTAMINATED QUICKLY .268
S-10 FUEL CONSUMPTION IS EXCESSIVE .269
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN .270
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) 271
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL) 272
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 273
S-15 ABNORMAL NOISE IS MADE 274
S-16 VIBRATION IS EXCESSIVE 275
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEMS (H MODE) .276
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC AND MECHANICAL SYSTEMS) .277
H-1 MACHINE LACKS POWER (LACKS DRAWBAR PULL) .279
H-2 MACHINE DOES NOT MOVE (2ND, 3RD, ENGINE RUNNING) .281
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE .283
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION (FORWARD OR IN REVERSE) 285
H-5 TIME LAG S EXCESSIVE WHEN SHIFTING GEAR OR CHANGING DIRECTION 286
H-6 MACHINE DOES NOT TURN (CAN TRAVEL IN STRAIGHT LINE) 287
H-7 MACHINE TURNS ONLY IN ONE DIRECTION (LEFT OR RIGHT) [JOYSTICK (STEERING, DIRECTIONAL, SPEED LEVEL) OPERATED] .288
H-8 MACHINE TURNS TOO FAR 289
H-9 BRAKES DO NOT WORK .290
H-10 POWER TRAIN OIL OVERHEATS .291
H-101 ALL WORK EQUIPMENT SPEEDS ARE SLOW .293
H-102 WORK EQUIPMENT DOES NOT MOVE .295
H-103 BLADE LIFT SPEED IS SLOW OR LACKS POWER 296
H-104 BLADE TILT SPEED IS SLOW OR LACKS POWER 296
H-105 RIPPER LIFT SPEED IS SLOW OR LACKS POWER .297
H-106 RIPPER TILT SPEED IS SLOW OR LACKS POWER .297
H-107 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 298
H-108 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 298
H-109 EXCESSIVE HYDRAULIC DRIFT OF RIPPER 299
H-110 PIN-PULLER CYLINDER DOES NOT WORK 299
H-111 ABNORMAL NOISE FROM AROUND HYDRAULIC PUMP 300
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) .301
M-1 WHEN STARTING SWITCH IS TURNED ON, NO DISPLAY IS GIVEN ON MONITOR PANEL) .302
M-2 WHEN STARTING SWITCH IS TURNED ON, MONITOR PANEL LAMPS ALL LIGHT UP BUT DO NOT GO OUT 302
M-3 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CAUTION ITEMS FLASH (WHEN THERE IS NO ABNORMALITY IN CHECK ITEMS OR ENGINE) .303
a) (BATTERY CHARGE) FLASHES 303
b) (ENGINE OIL PRESSURE) FLASHES .303
c) (COOLANT TEMPERATURE) FLASHES .304
d) (POWER TRAIN OIL TEMPERATURE) FLASHES .305
M-4 ABNORMALITY IN (PREHEATING) 306
a) PREHEATING MONITOR LAMP DOES NOT LIGHT UP .306
b) PREHEATING MONITOR LAMP STAYS LIGHTED UP 306
M-5 ABNORMALITY IN BUZZER 307
a) CAUTION ITEM FLASHES BUT BUZZER DOES NOT SOUND OR BUZZER DOES NOT SOUND FOR 1 SEC. WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) .307
b) MONITOR DISPLAY IS NORMAL BUT BUZZER SOUNDS .307
M-6 ABNORMALITY IN WARNING LAMP 308
a) CAUTION ITEM FLASHES BUT WARNING LAMP DOES NOT FLASH, OR WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), WARNING LAMP DOES NOT LIGHT UP FOR 1 SECOND 308
b) MONITOR DISPLAY IS NORMAL BUT WARNING LAMP LIGHTS UP 308
M-7 ABNORMALITY IN GAUGE 309
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE .309
b) ABNORMALITY IN POWER TRAIN (TORQUE CONVERTER) OIL TEMPERATURE GAUGE .309
c) ABNORMALITY IN FUEL LEVEL GAUGE .310
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED 311
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMP, WORKING LAMP ARE NORMAL) .312
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 313
E-1 ENGINE DOES NOT START 314
E-2 DEFECTIVE OPERATION OF APS .316
a) PREHEATING MONITOR LAMP DOES NOT LIGHT UP DURING PREHEATING .316
b) PREHEATING MONITOR LAMP STAYS LIGHTED UP AFTER PREHEATING IS COMPLETED 316
c) PREHEATING MONITOR LAMP FLASHES AFTER PREHEATING IS COMPLETED .317
d) PREHEATING MONITOR LAMP LIGHTS UP WHEN ENGINE IS STARTED (STARTING SWITCH AT START) AFTER PREHEATING IS COMPLETED .317
e) APS IS NOT ACTUATED WHEN WATER TEMPERATURE IS BELOW 20℃ .318
f) APS IS ACTUATED WHEN WATER TEMPERATURE IS ABOVE 20℃ .320
g) APS IS ACTUATED WHEN WATER TEMPERATURE IS BELOW 20℃ BUT APS SWITCH IS NOT TURNED ON .320
E-3 DEFECTIVE OPERATION OF BACK-UP ALARM .321
a) BACK-UP ALARM DOES NOT SOUND 321
b) BACK-UP ALARM DOS NOT STOP SOUNDING .321
E-4 LAMPS DO NOT LIGHT UP 322
a) FRONT LAMPS .322
b) WORKING LAMPS 322
c) REAR LAMPS (RIPPER LAMP) 324
E-5 PIN-PULLER CYLINDER DOES NOT WORK (ONLY MACHINES EQUIPPED WITH GIANT RIPPER) .325
30 DISASSEMBLY AND ASSEMBLY 326
HOW TO READ THIS MANUAL 329
PRECAUTIONS WHEN CARRYING OUT OPERATION 331
SPECIAL TOOL LIST 333
SKETCH OF SPECIAL TOOLS 343
STARTING MOTOR .350
REMOVAL 350
INSTALLATION .350
ALTERNATOR .351
REMOVAL 351
INSTALLATION .351
ENGINE OIL COOLER 352
REMOVAL 352
INSTALLATION .353
FUEL INJECTION PUMP 354
REMOVAL .354
INSTALLATION .354
WATER PUMP .355
REMOVAL .355
INSTALLATION .355
THERMOSTAT .356
REMOVAL 356
INSTALLATION .356
TURBOCHARGER .357
REMOVAL 357
INSTALLATION .358
AFTERCOOLER CORE .359
REMOVAL 359
INSTALLATION .360
NOZZLE HOLDER 361
REMOVAL 361
INSTALLATION .361
ENGINE FRONT SEAL 362
REMOVAL 362
INSTALLATION .362
ENGINE REAR SEAL .364
REMOVAL 364
INSTALLATION .364
CYLINDER HEAD 366
REMOVAL 366
INSTALLATION .371
FUEL TANK 373
REMOVAL 373
INSTALLATION .373
RADIATOR .374
REMOVAL 374
INSTALLATION .375
RADIATOR GUARD 376
REMOVAL 376
INSTALLATION .378
ENGINE .379
REMOVAL 379
INSTALLATION .384
DAMPER .385
REMOVAL 385
INSTALLATION .388
DISASSEMBLY 390
ASSEMBLY .391
POWER TRAIN UNIT .393
REMOVAL 393
INSTALLATION .397
DISCONNECTION 398
CONNECTION .403
PTO 405
DISASSEMBLY 405
ASSEMBLY .409
TORQUE CONVERTER .413
DISASSEMBLY 413
ASSEMBLY .419
TORQFLOW TRANSMISSION 425
DISASSEMBLY 425
ASSEMBLY .441
STEERING CASE 458
DISASSEMBLY 458
ASSEMBLY .466
POWER TRAIN,LUBRICATION PUMP .476
REMOVAL 476
INSTALLATION .476
SCAVENGING PUMP 477
REMOVAL 477
INSTALLATION .477
TORQUE CONVERTER OIL COOLER 478
REMOVAL 478
INSTALLATION .478
TORQUE CONVERTER VALVE .479
REMOVAL 479
INSTALLATION .479
DISASSEMBLY 480
ASSEMBLY .481
TRANSMISSION CONTROL VALVE .482
REMOVAL 482
INSTALLATION .482
DISASSEMBLY 483
ASSEMBLY .484
TRANSMISSION LUBRICATION VALVE .485
REMOVAL 485
INSTALLATION .485
DISASSEMBLY 485
ASSEMBLY .485
STEERING CONTROL VALVE .486
REMOVAL 486
INSTALLATION .486
DISASSEMBLY 487
ASSEMBLY .489
FINAL DRIVE .490
REMOVAL 490
INSTALLATION .490
DISASSEMBLY 491
ASSEMBLY .497
TACK FRAME .506
REMOVAL 506
INSTALLATION .506
IDLER ASSEMBLY .508
REMOVAL 508
INSTALLATION .508
DISASSEMBLY 509
ASSEMBLY .509
RECOIL SPRING 513
REMOVAL 513
INSTALLATION .513
DISASSEMBLY 517
ASSEMBLY .517
TRACK ROLLER .519
REMOVAL 519
INSTALLATION .519
DISASSEMBLY 522
ASSEMBLY .522
BOGIE ASSEMBLY .525
REMOVAL 525
INSTALLATION .525
DISASSEMBLY 530
ASSEMBLY .530
1ST BOGIE ASSEMBLY .532
REMOVAL 532
INSTALLATION .532
TRACK SHOE .537
CHECK BEFORE EXPANDING .537
EXPANDING 538
INSTALLATION .539
WHOLE DISASSEMBLY 540
WHOLE ASSEMBLY .540
1. WHEN RECYCLING FOR LUBRICATED TRACK .543
2. WHEN RECYCLING FOR GREASE-FILLED TRACK 552
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS 557
ONE LINK .558
FIELD DISASSEMBLY 558
FIELD ASSEMBLY .560
MASTER LINK 562
FIELD DISASSEMBLY 562
FIELD ASSEMBLY .562
PIVOT SHAFT ASSEMBLY .567
REMOVAL 567
INSTALLATION .567
EQUALIZER BAR 568
REMOVAL 568
INSTALLATION .568
EQUALIZER BAR BUSHING 571
DISASSEMBLY 571
ASSEMBLY .571
SEGMENT TOOTH 573
REMOVAL .573
INSTALLATION .573
HYDRAULIC TANK .574
REMOVAL 574
INSTALLATION .576
WORK EQUIPMENT,PPC PUMP 577
REMOVAL 577
INSTALLATION .577
BLADE LIFT VALVE .578
REMOVAL 578
INSTALLATION .579
DISASSEMBLY 580
ASSEMBLY .581
BLADE TILT,RIPPER LO VALVE .582
REMOVAL 582
INSTALLATION .583
DISASSEMBLY 584
ASSEMBLY .584
RIPPER HI VALVE 586
REMOVAL 586
INSTALLATION .586
DISASSEMBLY 587
ASSEMBLY .587
PPC CHARGE VALVE .589
REMOVAL 589
INSTALLATION .589
DISASSEMBLY 587
ASSEMBLY .587
BLADE PPC VALVE 591
REMOVAL 591
INSTALLATION .592
DISASSEMBLY 593
ASSEMBLY .594
RIPPER PPC VALVE .596
REMOVAL 596
INSTALLATION .597
DISASSEMBLY 598
ASSEMBLY .599
BLADE LIFT CYLINDER 600
REMOVAL 600
INSTALLATION .600
BLADE TILT CYLINDER 601
REMOVAL 601
INSTALLATION .601
RIPPER LIFT CYLINDER .602
REMOVAL 602
INSTALLATION .602
RIPPER TILT CYLINDER .603
REMOVAL 603
INSTALLATION .603
HYDRAULIC CYLINDER .604
DISASSEMBLY 604
ASSEMBLY .607
RIPPER PIN-PULLER 610
REMOVAL 610
INSTALLATION .610
DISASSEMBLY 611
ASSEMBLY .612
BLADE 614
REMOVAL 614
INSTALLATION .615
DISASSEMBLY 616
ASSEMBLY .618
GIANT RIPPER .620
DISASSEMBLY 620
ASSEMBLY .622
ROPS GUARD .624
REMOVAL 624
INSTALLATION .624
OPERATOR’S CAB .625
REMOVAL 625
INSTALLATION .625
FLOOR FRAME 626
REMOVAL 626
INSTALLATION .630
DASHBOARD 632
REMOVAL 632
INSTALLATION .633
MONITOR PANEL 634
REMOVAL 634
INSTALLATION .634
APS CONTROLLER .635
REMOVAL 635
INSTALLATION .635
AIR CONDITIONER COMPRESSOR .636
REMOVAL 636
INSTALLATION .637
AIR CONDITIONER CONDENSER 638
REMOVAL 638
INSTALLATION .638
HOOD .639
REMOVAL 639
INSTALLATION .639
40 MAINTENANCE STANDARD 640
ENGINE MOUNT .641
DAMPER, UNIVERSAL JOINT 642
TORQUE CONVERTER .643
TORQUE CONVERTER VALVE .644
TRANSMISSION .645
TRANSMISSION CONTROL VALVE .647
POWER TRAIN LUBRICATION + POWER TRAIN PUMP .649
SCAVENGING PUMP 650
TRANSFER, BEVEL PINION .651
BEVEL GEAR SHAFT, STEERING CLUTCH, BRAKE .652
STEERING CONTROL VALVE .654
FINAL DRIVE 656
MAIN FRAME .658
IDLER 660
TRACK ROLLER .662
CARRIER ROLLER .663
TRACK SHOE .664
WORK EQUIPMENT + PPC CHARGE PUMP .666
WORK EQUIPMENT CONTROL VALVE .668
PPC VALVE 672
PPC CHARGE VALVE .675
WORK EQUIPMENT CYLINDER 676
QUICK DROP VALVE .680
CYLINDER STAY 681
BLADE 682
RIPPER EQUIPMENT .687
90 OTHERS 691
ELECTRICAL CIRCUIT DIAGRAM (1/2) .692
ELECTRICAL CIRCUIT DIAGRAM (2/2) .693

DESCRIPTION:

Komatsu D375A-5 Crawler Bulldozer Shop Manual SEBM035200  – PDF DOWNLOAD

• MACHINE MODEL         SERIAL NUMBER
  D375A-5                          18200 and up

G.B 25/12/24