Komatsu Bulldozer D375A-6 service & repair manual

Description Komatsu Bulldozer D375A-6 service & repair manual

Komatsu Bulldozer D375A-6 pdf workshop service repair manual + operation & maintenance manual

Serial numbers:
60001 and up
60631 and up

Specifications, testing, troubleshooting, maintenance, technical documentation, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Forword 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

Specification
Specification and technical data
Specification drawing
Weight table
Table of fuel, coolant and lubricants

Structure and function
Engine and cooling system
Cooling system
Cooling fan pump
Cooling fan motor
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 lubrication 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
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)
Electric warming and preheating system
Pre-lubrication system

Standard value table
Standard service value table
Standard value table for engine
Standard value table for machine

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
Testing 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
Electrical 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 for electrical equipment 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
Pm Clinic service

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
Classification and procedures for troubleshooting numbers
Information in troubleshooting table
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Connection table for connector pin numbers
T-branch box and T-branch adapter table
Connector list and layout
Fuse locations table
Troubleshooting by failurecode
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

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, aftercooler, 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 engine assembly
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
Removal and installation of combustion type preheater assembly
Disassembly and assembly of preheater 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 recoil spring 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
Removal and installation of blade lift cylinder 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 operator’ 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

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

Appendix
CAB Heater
Heater component
Heater unit
Blower unit
FRESH/RECIRC air changeover damper
Heater control panel
Procedure for testing and troubleshooting
Circuit diagram and arrangement of connector pins
System diagram
Parts and connectors layout (CAB heater)
Testing temperature control
Testing FRESH/RECIRC air changeover
Testing relay
Troubleshooting chart
Information in troubleshooting table
Troubleshooting for power supply system (CAB heater does not operate)
Troubleshooting for blower motor system (Air does not come out or air flow is abnormal)
Troubleshooting for temperature control
Troubleshooting for FRESH/RECIRC air changeover
Additional heater does not operate
Combustion-type heater
Handling of on-board combustion preheater
Overall layout of preheating device and flow of engine coolant during preheating
Structure and function of combustion-type heater
Electrical circuit diagram
Operation and function
Overheat prevention function
Troubleshooting and repair instructions
Electrical circuit diagram of combustion-type heater

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Power train hydraulic diagrams and drawings
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electrical circuit diagrams
Electrical circuit diagram

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