Komatsu Crawler Dozers D375A-6 60001 and up Workshop Service Repair Manual

Original Illustrated Factory Workshop Service Manual for Komatsu Crawler Dozers D375. Original factory manuals for Komatsu Loaders, Dozers, Excavators contains high quality images, circuit diagrams and instructions to help you to operate, maintenance and repair your truck. All Manuals Printable, contains Searchable Text and Navigation Bookmarks Covered models: D375A-6 60001 and up Format: PDF, 1735 Pages Language: English Contents: 00 Index and Foreword Table of contents Table of contents Foreword and general information Safety notice How to read the shop manual Explanation of terms for maintenance standard Handling of electric equipment and hydraulic components Handling of connectors newly used for engines How to read electric wire code Precautions when carrying out work Method of disassembling and connecting push-pull type coupler Standard tightening torque table List of Abbreviation Conversion table 01 Specification Specification and technical data Specification drawing Specifications Weight table Table of fuel, coolant and lubricants 10 Structure,function and maintenance standard Engine and cooling system Cooling system Cooling fan pump Cooling fan motor Power train Power train Overall drawing of power train unit Power train hydraulic equipment arrangement drawing Damper and universal joint Torque converter and PTO Torque converter control valve Main relief valve and torque converter relief valve Lockup clutch ECMV and stator clutch ECMV Scavenging pump Transmission control PCCS lever Transmission Transmission ECMV Transmission lubricating oil relief valve Steering and brake control Transfer unit, bevel gear shaft and steering Steering control valve Steering clutch ECMV and Steering brake ECMV Parking brake valve Sudden stop prevention valve Final drive Undercarriage and frame Track frame Idler cushion Track roller bogie Main frame Suspension Hydraulic system Work equipment hydraulic piping diagram PPC control piping diagram Work equipment control Hydraulic tank Accumulator PPC lock valve PPC valve Piston valve Quick drop valve Pin puller switch Pin puller solenoid valve Blade control lever (only for the machine with dual tilt specification) Work equipment pump Control valve Self-pressure reducing valve Work equipment Cylinder stay Cab Cab mount Cab Electrical system Engine control Engine control system CRI engine control system Monitor system Machine monitor Lamp system Engine preheat (electrical intake air heater) control Palm command control system Sensor Vehicle health monitoring system (VHMS) ORBCOMM system 20 Standard value table Standard service value table Standard value table for engine Standard value table for machine 30 Testing and adjusting Tools for testing, adjusting, and troubleshooting Diagnosis equipment list Engine and cooling system Testing engine speed Testing intake air pressure (boost pressure) Testing exhaust temperature Testing exhaust gas color Adjusting valve clearance Measuring compression pressure Testing blow-by pressure Testing engine oil pressure Testing EGR valve drive oil pressure Handling of fuel system devices Releasing residual pressure from fuel system Testing fuel pressure Handling of reduced cylinder mode operation Handling of no injection cranking operation Testing leakage from pressure limiter and return rate from injector Bleeding air from fuel circuit Testing fuel circuit for leakage Replacing and adjusting alternator and air conditioner compressor belt Measuring fan speed Testing fan circuit oil pressure Bleeding air from fan pump Adjusting fuel control dial and decelerator pedal Power train Testing power train oil pressure Adjusting transmission output speed sensor Simple test procedure for brake performance Adjusting brake pedal and parking brake lever Adjusting position of pccs lever console Emergency escape method when there is failure in power train Undercarriage and frame Inspecting wear of sprocket Testing and adjusting track shoe tension Hydraulic system Measuring and adjusting work equipment oil pressure Testing control circuit main pressure Testing PPC valve output pressure Adjusting play of PPC valve Testing output pressure of ripper pin-puller solenoid valve Checking location of cause of hydraulic drift of blade and ripper Testing leakage inside work equipment cylinder Releasing remaining pressure in work equipment cylinders Bleeding air from work equipment cylinders Adjusting ripper lever position Work equipment Adjusting work equipment lock lever Adjusting blade Cab and its attachments Testing and adjusting operator's cab Testing and adjusting operator's seat isolator Electrial system Special functions of machine monitor (EMMS) Handling of voltage circuit of engine controller Adjustment method when controller has been replaced Preparation work for troubleshooting of electrical system Inspection procedure of diode Handling of optional devices Request for opening ORBCOMM terminal Initialization procedures for VHMS controller Using method of KOMTRAX functions of ORBCOMM terminal Precautions for replacing VHMS controller Pm Clinic service 40 Troubleshooting General Information on troubleshooting Points to remember when troubleshooting Sequence of events in troubleshooting Checks before troubleshooting Classification and procedures for troubleshooting Failure codes table Phenomena and troubleshooting numbers Information in troubleshooting table Troubleshooting method for disconnecting wiring harness of pressure sensor system Connectors table and arrangement drawing Connection table for connector pin numbers T-branch box and T-branch adapter table Fuse locations table Troubleshooting by failure code Troubleshooting of electrical system (E-mode) Information contained in troubleshooting table Troubleshooting of hydraulic and mechanical system (H-mode) Information in troubleshooting table List of Failure Modes and Causes Troubleshooting of engine (S-mode) Method of using troubleshooting chart 50 Disassembly and assembly General information on disassembly and assembly How to read this manual Coating materials list Special tools list Sketches of special tools Engine and cooling system Removal and installation of fuel supply pump assembly Removal and installation of fuel injector assembly Removal and installation of cylinder head assembly Removal and installation of radiator guard assembly Removal and installation of cooling assembly (radiator, after cooler, and hydraulic oil cooler) Removal and installation of radiator Removal and installation of hydraulic oil cooler Removal and installation of aftercooler Removal and installation of engineassembly Removal and installation of engine hood assembly Removal and installation of engine front seal Removal and installation of engine rear seal Removal and installation of fan drive assembly Removal and installation of fan motor assembly Removal and installation of fuel tank assembly Power train Removal and installation of damper assembly Disassembly and assembly of damper assembly Removal and installation of power train unit assembly Disconnection and connection of power train unit assembly Disassembly and assembly of PTO assembly Disassembly and assembly of torque converter assembly Disassembly and assembly of TORQFLOW transmission assembly Disassembly and assembly of steering case assembly Removal and installation of power train pump and lubrication pump assembly Removal and installation of scavenging pump assembly Removal and installation of final drive assembly Disassembly and assembly of final drive assembly Undercarriage and frame Removal and installation of track frame assembly Removal and installation of idler assembly Disassembly and assembly of idler assembly Removal and installation of recoil spring assembly Disassembly and assembly of recoilspring assembly Removal and installation of track roller assembly Disassembly and assembly of track roller assembly Removal and installation of carrier roller assembly Disassembly and assembly of carrier roller assembly Removal and installation of bogie assembly Disassembly and assembly of bogie assembly Removal and installation of first bogie assembly Separation and connection of track shoe assembly Overall disassembly and assembly of track shoe Link press press-fitting jig dimensions Disassembly and assembly of one link assembly in the field Disassembly and assembly of master link Removal and installation of pivot shaft assembly Removal and installation of equalizer bar Disassembly and assembly of equalizer bar bushing Removal and installation of segment tooth Hydraulic system Removal and installation of hydraulic tank assembly Removal and installation of work equipment pump assembly Removal and installation of fan pump assembly Removal and installation of control valve assembly Disassembly and assembly of control valve assembly Disassembly and assembly of blade PPC valve assembly Disassembly and assembly of ripper PPC valve assembly Disassembly and assembly of hydraulic cylinder assembly Disassembly and assembly of ripper pin puller cylinder assembly Work equipment Removal and installation of blade assembly Disassembly and assembly of blade assembly Disassembly and assembly of giant ripper assembly Cab and its attachments Removal and installation of ROPS guard Removal and installation of operators cab assembly Removal and installation of floor frame assembly Removal and installation of air conditioner unit assembly Removal and installation of operator's seat isolator Disassembly and assembly of operator's seat isolator Electrical system Removal and installation of transmission controller assembly and steering controller assembly Removal and installation of engine controller assembly Removal and installation of VHMS controller assembly Removal and installation of machine monitor assembly 60 Maintenance Standard Engine and cooling system Engine mount Cooling fan pump Cooling fan motor Power train Power train unit Damper and universal joint Torque converter and PTO Main relief valve and torque converter relief valve Lockup clutch ECMV and stator clutch ECMV Scavenging pump Transmission control Transmission Transmission lubricating oil relief valve Power train and lubrication pump Transfer, bevel gear shaft and steering unit Steering control valve Steering clutch ECMV and steering brake ECMV Parking brake valve Final drive Sprocket Undercarriage and frame Track frame Idler cushion Idler Track roller Carrier roller Track roller bogie Track shoe Main frame Suspension Hydraulic system PPC valve Hydraulic cylinder Quick drop valve Work equipment pump Control valve Self-pressure reducing valve Work equipment Cylinder stay Blade Cutting edge and end bit Ripper 80 Appendix Air Conditioner Caution about refrigerant Air conditioner component Configuration and function of refrigeration cycle Outline of refrigeration cycle Air conditioner unit Blower unit FRESH/RECIRC air changeover damper Compressor Condenser Receiver drier Air conditioner control panel Procedure for testing and troubleshooting Circuit diagram and arrangement of connector pins System diagram Part and connector locations Testing temperature control Testing FRESH/RECIC air changeover Testing relay Troubleshooting chart 1 Troubleshooting chart 2 Information in troubleshooting table Troubleshooting for power supply system (Air conditioner does not operate) Troubleshooting for compressor system (Air is not cooled) Troubleshooting for blower motor system (Air does not comeout or air flow is abnormal) Troubleshooting for temperature control Troubleshooting for FRESH/RECIRC air changeover Troubleshooting with gauge pressure Connection of service tool Precautions for disconnecting and connecting Handling of compressor oil 90 Diagrams and Drawings Hydraulic diagrams and drawings Symbols used in hydraulic circuit diagrams Power train hydraulic circuit diagram Hydraulic circuit diagram Electrical diagrams and drawings Symbols use in electric circuit diagrams Electrical circuit diagram Index