Komatsu Bulldozer D575A-2 Shop Manual SEBM006506 – PDF DOWNLOAD

Description

Komatsu Bulldozer D575A-2 Shop Manual SEBM006506 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Bulldozer D575A-2 Shop Manual SEBM006506 – PDF DOWNLOAD

Language : English
Pages :812
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Bulldozer D575A-2 Shop Manual SEBM006506 – PDF DOWNLOAD

Serial Number: D575A-2 – 10012 and up

FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the
serviceman an accurate understanding of the product and by showing him the correct way to perform
repairs and make judgements. Make sure you understand the contents of this manual and use it to full
effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a
service workshop. For ease of understanding, the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give
an understanding of the structure, but also serves as reference material for troubleshooting.
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” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or
assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting disassembled parts.

TABLE OF CONTENTS:

Komatsu Bulldozer D575A-2 Shop Manual SEBM006506 – PDF DOWNLOAD

Serial Number: D575A-2 – 10012 and up

MAIN MENU 0
CONTENTS 2
01 GENERAL 23
SPECIFICATION DRAWING 24
SPECIFICATIONS 25
WEIGHT TABLE 28
FUEL, COOLANT AND LUBRICANTS 30
10 STRUCTURE AND FUNCTION 32
RADIATOR, OIL COOLER, COOLING FAN 33
FUEL PIPING DRAWING 35
ENGINE CONTROL 36
IN-LINE SERVO VALVE 37
POWER TRAIN SYSTEM 40
POWER TRAIN SKELTON 41
POWER TRAIN HYDRAULIC PIPING 42
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS 44
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 45
DAMPER 46
TORQUE CONVERTER, PTO 47
TORQUE CONVERTER VALVE 52
TORQUE CONVERTER FILTER 61
TRANSMISSION CONTROL 62
TRANSMISSION 63
TRANSMISSION CONTROL VALVE 69
STEERING CLUTCH, BRAKE CONTROL 84
STEERING CONTROL VALVE 85
STEERING CLUTCH, STEERING BRAKE 91
FINAL DRIVE 96
TRACK FRAME102
RECOIL SPRING104
TRACK ROLLER BOGIE105
SUSPENSION106
HYDRAULIC PIPING DIAGRAM FOR WORK EQUIPMENT 108
CENTRALIZED OIL PRESSURE DETECTION PIPING DIAGRAM 111
HYDRAULIC CIRCUIT SCHEMATICS FOR WORK EQUIPMENT 112
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT113
HYDRAULIC TANK 114
ACCUMULATOR FOR WORK EQUIPMENT CIRCUIT115
PITCH, TILT SELECTOR SOLENOID VALVE ASSEMBLY 116
PITCH BACK (PITCH DUMP) SOLENOID VALVE 117
PPC VALVE 119
ACCUMULATOR FOR PPC CIRCUIT123
PPC RELIEF VALVE 124
MAIN CONTROL VALVE 125
PITCH SELECTOR SOLENOID VALVE 129
PITCH PRIORITY SOLENOID VALVE 130
PITCH ASSIST SOLENOID VALVE 131
BLADE CONTROL KNOB 132
PISTON VALVE FOR BLADE LIFT CYLINDER 133
QUICK DROP VALVE FOR BLADE LIFT CYLINDER 134
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT135
CYLINDER STAY, YOKE143
WORK EQUIPMENT 145
COUNTERWEIGHT147
CAB 148
AIR CONDITIONER150
ACTUAL ELECTRIC WIRING DIAGRAM152
ELECTRICAL CIRCUIT DIAGRAM 154
EVMS (Electronic Vehicle Monitoring System) 158
TORQUE CONVERTER LOCK-UP, BLADE CONTROL SYSTEM 170
20 TESTING AND ADJUSTING178
STANDARD VALUE TABLE FOR ENGINE179
STANDARD VALUE TABLE FOR CHASSIS 180
STANDARD VALUE TABLE FOR ELECTRICAL RELATED PARTS 186
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 192
ADJUSTING VALVE CLEARANCE 194
MEASURING COMPRESSION PRESSURE 195
TESTING AND ADJUSTING FUEL INJECTION TIMING 196
ADJUSTING FUEL INJECTION PUMP RACK LINKAGE 198
MEASURING ENGINE OIL PRESSURE 199
MEASURING ENGINE SPEED 199
MEASURING EXHAUST COLOR 200
TESTING AND ADJUSTING FAN BELT TENSION 201
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 202
MEASURING EXHAUST TEMPERATURE 203
MEASURING BLOW-BY 205
MEASURING COOLING FAN SPEED 206
MEASURING TORQUE CONVERTER STALL SPEED 207
MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL)208
MEASURING POWER TRAIN OIL PRESSURE209
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE213
PROCEDURE FOR RELEASING STEERING BREAK213
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE (MAIN RELIEF AND PPC CIRCUIT) 214
MEASURING PPC VALVE OUTPUT PRESSURE217
ADJUSTING WORK EQUIPMENT, PPC VALVE 218
RELEASING AIR REMAINING IN HYDRAULIC CIRCUIT ON PPC VALVE 219
BLEEDING AIR FROM HYDRAULIC CYLINDER 219
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE220
MEASURING LEAKAGE INSIDE CYLINDER221
ADJUSTING FUEL CONTROL LINKAGE 222
ADJUSTMENT OF GEARSHIFT LEVER LINKAGE 225
ADJUSTMENT OF STEERING LEVER LINKAGE227
ADJUSTMENT OF BRAKE PEDAL LINKAGE 229
PROCEDURE FOR TESTING SENSORS 231
TROUBLESHOOTING233
POINTS TO REMEMBER WHEN TROUBLESHOOTING 234
SEQUENCE OF EVENTS IN TROUBLESHOOTING 235
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE236
CHECKS BEFORE TROUBLESHOOTING 244
METHOD OF USING TROUBLESHOOTING CHARTS 245
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 251
LOCATION OF CONNECTOR, SENSOR255
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 257
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)267
TABLE OF FAILURE MODES AND CAUSES (ELECTRIC, HYDRAULIC, MECHANICAL SYSTEMS) 268
ELECTRICAL CIRCUIT DIAGRAM FOR STARTING SYSTEM 270
E-3 Engine does not start271
E-4 Tilt cannot be used (Pitch can be used)274
E-5 Pitch dozer cannot be used (Tilt can be used)274
E-6 Neither tilt nor pitch dozer can be used (Only left pitch cylinder can be operated)275
E-7 Head lamps do not light up277
a) Left head lamp does not light up277
b) Right head lamp does not light up277
E-8 Rear lamps do not light up278
E-9 Working lamp does not light up278
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)280
S-1 Starting performance is poor (Starting always takes time)281
S-2 Engine does not start282
(1) Engine does not turn282
(2) Engine turns but no exhaust smoke comes out (Fuel is not being injected)283
(3) Exhaust smoke comes out but engine does not start (Fuel is being injected)284
S-3 Engine does not pick-up smoothly (follow-up is poor)285
S-4 Engine stops during operations286
S-5 Engine does not rotate smoothly (Hunting)287
S-6 Engine lacks output (No power)288
S-7 Exhaust smoke is black (Incomplete combustion)289
S-8 Oil consumption is excessive (Or exhaust smoke is blue)290
S-9 Oil becomes contaminated quickly291
S-10 Fuel consumption is excessive292
S-11 Oil is in cooling water, or water spurts back, or water level goes down293
S-12 Oil pressure caution lamp lights up (Drop in oil pressure)294
S-13 Oil level rises295
S-14 Water temperature becomes too high (Overheating)296
S-15 Abnormal noise is made297
S-16 Vibration is excessive298
TROUBLESHOOTING OF WORK EQUIPMENT, LOCK-UP CONTROLLER SYSTEM (E MODE)299
MONITOR PANEL, CONTROLLER DISPLAY METHOD300
ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE308
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT, LOCK-UP CONTROLLER SYSTEM316
E-101 [01] Oil Drop in controller power source voltage317
E-102 [02] Incorrect standard value for yoke angle318
E-103 [03] Transmission slips319
E-104 [04] Engine overrun319
E-105 [10, 11,12] Engine speed sensor system320
E-106 [1A, 1C] Bevel gear speed sensor system322
E-107 [20,21] Left yoke angle sensor system324
E-108 [22,23] Right yoke angle sensor system326
E-109 [30] Blade lift oil pressure switch system328
E-110 [31] Pitch dump switch system329
E-111 [32] Pitch back switch system331
E-112 [40,41] Transmission F (FORWARD) oil pressure switch system333
E-113 [40,42] Transmission R (REVERSE) oil pressure switch system335
E-114 [45,46] Transmission 1 (1st) oil pressure switch system337
E-115 [45,47] Transmission 2 (2nd) oil pressure switch system339
E-116 [45,46] Transmission 3 (3rd) oil pressure switch system341
E-117 [4A, 4C, 4E] Transmission modulating oil pressure switch system343
E-118 [60,61] Pitch dump solenoid system345
E-119 [62,63] Pitch back solenoid system347
E-120 [64,65] Pitch selector solenoid system349
E-121 [66,67] Left tilt limit solenoid system350
E-122 [68, 69] Right tilt limit solenoid system351
E-123 [6A, 6C] Pitch priority solenoid system352
E-124 [6E, 6F] Pitch assist pump relay system353
E-125 [70,71] Lock-up solenoid system355
E-126 [80,81] Alarm buzzer system357
E-127 [8A] System abnormality lamp system360
E-128 [8C] Lock-up lamp display lamp system361
E-129 [F0] Monitor caution lamp system362
E-130 [F1] Buzzer cancel switch system364
E-131 Lock-up switch system365
E-132 Pitch assist pump solenoid (left) system366
E-133 Pitch assist pump solenoid (right) system367
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)368
TABLE OF FAILURE MODES AND CAUSES (ELECTRIC, HYDRAULIC, MECHANICAL SYSTEMS)369
H-1 Brakes do not work371
H-2 Machine does not turn (Machine can travel only in a straight line)372
H-3 There is travel deviation373
H-4 Machine turns only in one direction (Lever operated)374
H-5 Time lag is excessive375
H-6 Machine travels only in one direction (Forward or in reverse)377
H-7 Machine does not move (2nd, 3rd)378
H-8 Machine does not move in any speed range380
H-9 Torque converter overheats382
H-10 Abnormal noise from around hydraulic pump384
H-11 Blade RAISE speed slow or work equipment lacks power385
H-12 Blade pitch speed slow or blade pitch lacks power386
H-13 Excessive hydraulic drift of blade387
H-14 Excessive hydraulic drift of blade pitch387
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)388
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR)389
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM391
M-1 No display appears on the monitor panel when the starting switch is ON392
M-2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out392
M-3 When starting switch is ON (Engine stopped), CHECK items show abnormality (The radiator and engine oil level in the CHECK it393
a) Abnormality in radiator water level monitor393
b) Abnormality in engine oil level monitor394
M-4 When starting switch is ON and engine is started, CAUTION items flash395
a) Charge level monitor flashes395
b) Engine oil pressure monitor flashes395
c) Coolant level monitor flashes395
d) Coolant temperature monitor flashes395
e) Torque converter oil temperature monitor flashes396
f) Hydraulic oil temperature monitor flashes396
M-5 Abnormality in buzzer399
a) CAUTION items are flashing, but buzzer does not sound399
b) Monitor panel does not display any abnormality, but buzzer sounds399
M-6 Abnormality in gauge401
a) Abnormality in coolant temperature gauge401
b) Abnormality in torque converter oil temperature gauge402
c) Fuel gauge always displays FULL403
M-7 Service meter does not move after engine is started404
M-8 Monitor panel lighting does not light up (Liquid crystal display is normal)405
M-9 When lock-up switch is pressed, lock-up is not actuated (LEDs on panel are normal)406
30 DISASSEMBLY AND ASSEMBLY407
METHOD OF USING MANUAL409
PRECAUTIONS WHEN CARRYING OUT OPERATION411
SPECIAL TOOL LIST413
STARTING MOTOR426
REMOVAL AND INSTALLATION426
ALTERNATOR428
REMOVAL AND INSTALLATION428
ENGINE OIL COOLER429
REMOVAL 429
INSTALLATION 430
FUEL INJECTION PUMP431
REMOVAL431
INSTALLATION433
WATER PUMP434
REMOVAL AND INSTALLATION 434
TURBOCHARGER435
REMOVAL AND INSTALLATION435
AFTER-COOLER CORE437
REMOVAL AND INSTALLATION437
NOZZLE HOLDER438
REMOVAL 438
INSTALLATION 439
CYLINDER HEAD440
REMOVAL 440
INSTALLATION 444
POWER TRAIN OIL COOLER446
REMOVAL 446
INSTALLATION448
HYDRAULIC COOLER449
REMOVAL AND INSTALLATION449
RADIATOR450
REMOVAL 450
INSTALLATION 453
FAN DRIVE SUPPORT454
REMOVAL 454
INSTALLATION 456
FAN DRIVE PULLEY457
REMOVAL AND INSTALLATION457
DISASSEMBLY 458
ASSEMBLY 459
REMOVAL 461
INSTALLATION 462
DISASSEMBLY 463
ASSEMBLY 464
ENGINE465
REMOVAL 465
INSTALLATION 468
DAMPER469
REMOVAL469
INSTALLATION 470
DISASSEMBLY 471
ASSEMBLY 472
POWER TRAIN474
REMOVAL474
INSTALLATION 479
PTO, TORQUE CONVERTER481
REMOVAL 481
INSTALLATION 484
DISCONNECTION 485
CONNECTION 486
PTO487
DISASSEMBLY 487
ASSEMBLY 492
TORQUE CONVERTER498
DISASSEMBLY 498
ASSEMBLY 503
TORQFLOW TRANSMISSION510
REMOVAL 510
INSTALLATION 511
DISASSEMBLY 512
ASSEMBLY 523
STEERING CASE537
REMOVAL 537
INSTALLATION 538
DISASSEMBLY 539
ASSEMBLY 545
STEERING CLUTCH555
DISASSEMBLY 555
ASSEMBLY 557
STEERING BRAKE558
DISASSEMBLY 558
ASSEMBLY 561
TORQUE CONVERTER VALVE567
REMOVAL AND INSTALLATION567
ASSEMBLY 570
DISASSEMBLY 568
TRANSMISSION CONTROL VALVE572
REMOVAL AND INSTALLATION572
DISASSEMBLY AND ASSEMBLY573
STEERING CONTROL VALVE582
REMOVAL AND INSTALLATION582
DISASSEMBLY 583
ASSEMBLY 585
POWER TRAIN PUMP587
REMOVAL AND INSTALLATION587
TRANSMISSION LUBRICATION PUMP588
REMOVAL AND INSTALLATION588
SCAVENGING PUMP589
REMOVAL AND INSTALLATION589
FINAL DRIVE590
REMOVAL AND INSTALLATION590
DISASSEMBLY 591
ASSEMBLY 599
TRACK FRAME611
REMOVAL 611
INSTALLATION 613
RECOIL SPRING, TUBE614
REMOVAL 614
INSTALLATION 615
DISASSEMBLY 616
ASSEMBLY 622
IDLER YOKE, CYLINDER625
DISASSEMBLY 625
ASSEMBLY 626
IDLER628
REMOVAL 628
INSTALLATION 629
DISASSEMBLY 630
ASSEMBLY 632
TRACK ROLLER635
REMOVAL 635
INSTALLATION636
DISASSEMBLY 637
ASSEMBLY 639
CARRIER ROLLER641
REMOVAL AND INSTALLATION641
DISASSEMBLY 642
ASSEMBLY 644
BOGIE647
REMOVAL647
INSTALLATION 648
DISASSEMBLY 648
ASSEMBLY652
TRACK SHOE655
CHECKING BEFORE REMOVAL655
REMOVAL 655
REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)658
INSTALLATION 659
DISASSEMBLY660
ASSEMBLY665
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS680
FIELD DISASSEMBLY OF ONE LINK681
DISASSEMBLY681
ASSEMBLY 683
MASTER LINK685
DISASSEMBLY 685
ASSEMBLY 687
ADJUSTING TRACK SHOE TENSION690
PIVOT SHAFT691
REMOVAL 691
INSTALLATION 691
EQUALIZER BAR692
REMOVAL692
INSTALLATION 694
SEGMENT TEETH697
REMOVAL 697
INSTALLATION 697
WORK EQUIPMENT PUMP698
REMOVAL AND INSTALLATION 698
WORK EQUIPMENT ASSIST, CONTROL PUMP699
REMOVAL AND INSTALLATION 699
BLADE VALVE700
REMOVAL AND INSTALLATION 700
DISASSEMBLY 702
ASSEMBLY 704
MAIN RELIEF VALVE706
DISASSEMBLY 706
ASSEMBLY 706
BLADE LIFT CYLINDER707
REMOVAL AND INSTALLATION 707
BLADE PITCH CYLINDER708
REMOVAL AND INSTALLATION 708
HYDRAULIC CYLINDER709
DISASSEMBLY709
ASSEMBLY 712
BLADE PPC VALVE715
REMOVAL AND INSTALLATION 715
DISASSEMBLY716
ASSEMBLY 716
BLADE718
REMOVAL 718
INSTALLATION719
DISASSEMBLY720
ASSEMBLY722
POTENTIOMETER724
REMOVAL AND INSTALLATION 724
OPERATOR’S COMPARTMENT FRAME726
REMOVAL 726
INSTALLATION 728
CAB729
REMOVAL 729
INSTALLATION 730
ROPS731
REMOVAL AND INSTALLATION 731
COUNTERWEIGHT FRAME732
REMOVAL AND INSTALLATION 732
BLADE LIFT CYLINDER SUPPORT733
REMOVAL 733
INSTALLATION 734
40 MAINTENANCE STANDARD735
ENGINE MOUNT736
DAMPER 737
TORQUE CONVERTER, PTO 738
TORQUE CONVERTER VALVE 740
TRANSMISSION742
TRANSMISSION CONTROL VALVE744
STEERING CONTROL VALVE748
STEERING CLUTCH, STEERING BRAKE750
FINAL DRIVE 754
TRACK FRAME756
RECOIL SPRING758
IDLER759
CARRIER ROLLER761
TRACK ROLLER763
TRACK ROLLER BOGIE765
TRACK SHOE 766
SUSPENSION771
HYDRAULIC PUMP773
PPC VALVE777
MAIN CONTROL VALVE 778
WORK EQUIPMENT CYLINDER779
CYLINDER STAY, YOKE 781
MAIN FRAME783
WORK EQUIPMENT785
COUNTERWEIGHT 788
90 OTHERS789
POWER TRAIN HYDRAULIC PIPING790
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS791
ENGINE RUNNING, TRANSMISSION SHIFT LEVER IN “NEUTRAL”, STEERING LEVERS AND BRAKE PEDAL NOT OPERATED791
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM792
TRANSMISSION793
HYDRAULIC PIPING DIAGRAM FOR WORK EQUIPMENT794
BLADE SYSTEM794
HYDRAULIC CIRCUIT SCHEMATICS FOR WORK EQUIPMENT795
ENGINE RUNNING, WORK EQUIPMENT CONTROL LEVER IN “HOLD”795
HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT796
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT797
BLADE RAISE797
BLADE LEFT TILT798
BLADE PITCH BACK799
BLADE PITCH DUMP 800
AIR CONDITIONER801
AIR CONDITIONER PIPING801
ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)802
ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)803
ELECTRICAL CIRCUIT DIAGRAM806
CHASSIS ELECTRICAL CIRCUIT (1/2)806
CHASSIS ELECTRICAL CIRCUIT (2/2)807
AIR CONDITIONER ELECTRICAL CIRCUIT808
TORQUE CONVERTER LOCK-UP, BLADE CONTROL SYSTEM809
LOCATION OF CONNECTOR, SENSOR810
ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT, LOCK-UP CONTROLLER SYSTEM811
ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM812

IMAGES PREVIEW OF THE MANUAL:

S.M 27/12/24