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Komatsu D50A-17, D50P-17, D53A-17, D53P-17 Crawler Bulldozer Shop Manual SEBM01301707 – PDF DOWNLOAD
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Komatsu D50A-17, D50P-17, D53A-17, D53P-17 Crawler Bulldozer Shop Manual
MODEL SERIAL NUMBER
D50A-17 80001 and up
D50P-17 80001 and up
D53A-17 80001 and up
D53P-17 80001 and up
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Description
Komatsu D50A-17, D50P-17, D53A-17, D53P-17 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D50A-17, D50P-17, D53A-17, D53P-17 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D50A-17, D50P-17, D53A-17, D53P-17
Serial Number: 80001 and up
Book Code: SEBM01301707
Language: English
Pages: 652
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D50A-17, D50P-17, D53A-17, D53P-17 Crawler Bulldozer Shop Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. 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 D50A-17, D50P-17, D53A-17, D53P-17 Crawler Bulldozer Shop Manual
COVER..................................................................................................................... 1 CONTENTS.................................................................................................................. 2 01 GENERAL................................................................................................................ 21 ASSEMBLY DRAWING...................................................................................................... 22 SPECIFICATIONS........................................................................................................ 24 WEIGHT TABLE.......................................................................................................... 36 TABLE OF FUEL, COOLANT AND LUBRICANTS................................................................................. 38 10 ENGINE................................................................................................................. 40 11 STRUCTURE AND FUNCTION............................................................................................. 40 RADIATOR AND OIL COOLER........................................................................................... 41 ENGINE MOUNT...................................................................................................... 44 ENGINE CONTROL.................................................................................................... 45 FUEL TANK......................................................................................................... 46 12 TESTING AND ADJUSTING.............................................................................................. 47 STANDARDS FOR TESTING AND ADJUSTING............................................................................... 48 TOOLS FOR TESTING AND ADJUSTING................................................................................... 51 ADJUSTMENT OF VALVE CLEARANCE..................................................................................... 52 MEASUREMENT OF COMPRESSION PRESSURE............................................................................... 53 TESTING AND ADJUSTING FUEL INJECTION TIMING....................................................................... 54 TESTING AND ADJUSTING FAN BELT TENSION............................................................................ 58 MEASURING BLOW-BY................................................................................................. 60 MEASURING EXHAUST GAS COLOR....................................................................................... 61 MEASURING ENGINE OIL PRESSURE..................................................................................... 62 MEASURING ENGINE SPEED............................................................................................ 62 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)......................................................................... 63 METHOD OF USING TROUBLESHOOTING CHARTS........................................................................ 64 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)................................................. 68 S-2 ENGINE DOES NOT START..................................................................................... 69 ①ENGINE DOES NOT TURN..................................................................................... 69 ②ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)................................. 70 ③EXHAUST SMOKE COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)............................... 71 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)...................................................... 72 S-4 ENGINE STOPS DURING OPERATIONS............................................................................ 73 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)................................................................. 74 S-6 ENGINE LACKS OUTPUT (NO POWER)............................................................................ 75 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)............................................................ 76 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)................................................... 77 S-9 OIL BECOMES CONTAMINATED QUICKLY.......................................................................... 78 S-10 FUEL CONSUMPTION IS EXCESSIVE............................................................................ 79 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.................................. 80 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................... 81 S-13 OIL LEVEL RISES (WATER, FUEL IN OIL ).................................................................... 82 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)......................................................... 83 S-15 ABNORMAL NOISE IS MADE................................................................................... 84 S-16 VIBRATION IS EXCESSIVE................................................................................... 85 13 DISASSEMBLY AND ASSEMBLY........................................................................................... 86 STARTING MOTOR.................................................................................................... 87 DISMOUNTING................................................................................................... 87 MOUNTING...................................................................................................... 87 REMOVAL....................................................................................................... 88 INSTALLATION.................................................................................................. 88 ALTERNATOR........................................................................................................ 89 DISMOUNTING................................................................................................... 89 MOUNTING...................................................................................................... 89 REMOVAL....................................................................................................... 90 INSTALLATION.................................................................................................. 90 ENGINE OIL COOLER................................................................................................. 91 DISMOUNTING................................................................................................... 91 MOUNTING...................................................................................................... 91 REMOVAL....................................................................................................... 92 INSTALLATION.................................................................................................. 92 FUEL INJECTION PUMP............................................................................................... 93 DISMOUNTING................................................................................................... 93 MOUNTING...................................................................................................... 93 REMOVAL....................................................................................................... 94 INSTALLATION.................................................................................................. 95 WATER PUMP........................................................................................................ 96 DISMOUNTING................................................................................................... 96 MOUNTING...................................................................................................... 96 REMOVAL....................................................................................................... 97 INSTALLATION.................................................................................................. 97 NOZZLE HOLDER..................................................................................................... 98 DISMOUNTING................................................................................................... 98 MOUNTING...................................................................................................... 98 REMOVAL....................................................................................................... 99 INSTALLATION.................................................................................................. 99 CYLINDER HEAD.....................................................................................................100 DISMOUNTING...................................................................................................100 MOUNTING......................................................................................................104 REMOVAL.......................................................................................................109 INSTALLATION..................................................................................................112 THERMOSTAT........................................................................................................114 REMOVAL.......................................................................................................114 INSTALLATION..................................................................................................114 ENGINE FRONT SEAL.................................................................................................115 REMOVAL.......................................................................................................115 INSTALLATION..................................................................................................115 ENGINE REAR SEAL..................................................................................................116 REMOVAL.......................................................................................................116 INSTALLATION..................................................................................................117 RADIATOR..........................................................................................................120 DISMOUNTING...................................................................................................120 MOUNTING......................................................................................................123 RADIATOR GUARD....................................................................................................126 DISMOUNTING...................................................................................................126 MOUNTING......................................................................................................129 REMOVAL.......................................................................................................132 INSTALLATION..................................................................................................133 ENGINE (D50)......................................................................................................134 DISMOUNTING...................................................................................................134 MOUNTING......................................................................................................138 20 POWER TRAIN............................................................................................................150 21 STRUCTURE AND FUNCTION.............................................................................................150 GENERAL...........................................................................................................151 POWER TRAIN HYDRAULIC SYSTEM (D50-17).............................................................................155 POWER TRAIN HYDRAULIC SYSTEM (D53-17).............................................................................157 MAIN CLUTCH.......................................................................................................159 MAIN CLUTCH PUMP..................................................................................................167 MAIN CLUTCH HYDRAULIC BOOSTER.....................................................................................168 TRANSMISSION......................................................................................................172 DAMPER AND UNIVERSAL JOINT........................................................................................183 TORQUE CONVERTER..................................................................................................185 TORQUE CONVERTER RELIEF VALVE.....................................................................................188 TORQFLOW TRANSMISSION.............................................................................................189 TORQFLOW TRANSMISSION CONTROL LINKAGE.............................................................................200 TORQFLOW HYDRAULIC SYSTEM.........................................................................................201 TORQFLOW HYDRAULIC CONTROL........................................................................................202 TRANSMISSION CONTROL VALVE........................................................................................204 TRANSMISSION LUBRICATING SYSTEM...................................................................................209 TRANSMISSION LUBRICATING VALVE....................................................................................210 TRANSMISSION PUMP.................................................................................................211 TRANSMISSION OIL FILTER...........................................................................................212 STEERING CLUTCH AND BRAKE PIPING..................................................................................213 STEERING CLUTCH AND BRAKE HYDRAULIC SYSTEM........................................................................214 STEERING CLUTCH AND BEVEL GEAR....................................................................................216 STEERING CONTROL VALVE............................................................................................218 STEERING BRAKE AND BOOSTER........................................................................................223 STEERING RELIEF VALVE.............................................................................................229 STEERING PUMP.....................................................................................................231 STEERING STRAINER.................................................................................................232 STEERING OIL FILTER...............................................................................................233 STEERING LEVER-CONTROL LINKAGE....................................................................................234 BRAKE PEDAL LINKAGE...............................................................................................235 FINAL DRIVE.......................................................................................................236 22 TESTING AND ADJUSTING..............................................................................................239 STANDARDS FOR TESTING AND ADJUSTING...............................................................................240 OIL PRESSURE MEASUREMENT LOCATIONS................................................................................246 OIL PRESSURE ADJUSTMENT LOCATIONS.................................................................................247 TESTING AND ADJUSTING MAIN CLUTCH.................................................................................248 ADJUSTING CLEARANCE BETWEEN BRAKE BAND AND DRUM...................................................................249 ADJUSTING STEERING LEVER TRAVEL...................................................................................250 ADJUSTING BRAKE PEDAL TRAVEL......................................................................................251 MEASURING TORQUE CONVERTER STALL..................................................................................252 TROUBLESHOOTING...................................................................................................253 LIST OF TROUBLESHOOTING TOOLS.................................................................................254 DIAGNOSTIC TABLES.............................................................................................255 1.HIGH OIL TEMPERATURE IN TORQUE CONVERTER................................................................255 2.THE MACHINE WILL NOT START..............................................................................256 3.WEAK TRACTION POWER OR SLOW MACHINE TRAVEL SPEED........................................................257 4.THE MACHINE MOVES WHEN THE ENGINE IS STARTED............................................................259 5.EXCESSIVE TIME LAG WHEN STARTING OFF OR CHANGING GEAR SPEEDS............................................260 6.THE MACHINE RECEIVERS SEVERE SHOCKS WHEN STARTING OFF OR WHEN CHANGING GEAR SPEEDS......................261 7.SHIFT LEVER SLIPS OUT...................................................................................261 8.CONTROL LEVER IS HEAVY TO SHIFT.........................................................................261 9.THE OIL LEVEL IN THE TRANSMISSION AND STEERING CLUTCH CASE GOES UP OR GOES DOWN.........................261 10.STEERING CLUTCH FAILS TO DISENGAGE.....................................................................262 11.STEERING CLUTCH SLIPS..................................................................................263 12.STEERING BRAKE DOES NOT WORK...........................................................................264 23 DISASSEMBLY AND ASSEMBLY...........................................................................................265 MAIN CLUTCH (D50).................................................................................................266 DISMOUNTING...................................................................................................266 MOUNTING......................................................................................................269 DISASSEMBLY...................................................................................................273 ASSEMBLY......................................................................................................277 MAIN CLUTCH BOOSTER (D50).........................................................................................281 DISMOUNTING...................................................................................................281 MOUNTING......................................................................................................283 DISASSEMBLY...................................................................................................285 ASSEMBLY......................................................................................................285 TRANSMISSION (D50)................................................................................................287 DISMOUNTING...................................................................................................287 MOUNTING......................................................................................................289 DISASSEMBLY...................................................................................................291 ASSEMBLY......................................................................................................298 DAMPER (D53)......................................................................................................305 DISMOUNTING...................................................................................................305 MOUNTING......................................................................................................307 TORQFLOW TRANSMISSION AND TORQUE CONVERTER (D53)..................................................................309 DISMOUNTING...................................................................................................309 MOUNTING......................................................................................................313 DISJOINTING...................................................................................................317 JOINTING......................................................................................................317 TORQUE CONVERTER (D53)............................................................................................318 DISASSEMBLY...................................................................................................318 ASSEMBLY......................................................................................................326 TORQUE CONVERTER RELIEF VALVE (D53)..............................................................................338 DISMOUNTING...................................................................................................338 MOUNTING......................................................................................................338 TORQFLOW TRANSMISSION (D53).......................................................................................339 DISASSEMBLY...................................................................................................339 ASSEMBLY......................................................................................................352 TRANSMISSION CONTROL VALVE (D53)..................................................................................366 DISMOUNTING...................................................................................................366 MOUNTING......................................................................................................366 DISASSEMBLY...................................................................................................367 ASSEMBLY......................................................................................................367 BEVEL PINION......................................................................................................371 DISMOUNTING...................................................................................................371 MOUNTING......................................................................................................371 DISASSEMBLY...................................................................................................372 ASSEMBLY......................................................................................................373 BEVEL GEAR SHAFT AND STEERING CLUTCH..............................................................................375 DISMOUNTING...................................................................................................375 MOUNTING......................................................................................................380 DISASSEMBLY...................................................................................................385 ASSEMBLY......................................................................................................391 STEERING BRAKE BOOSTER............................................................................................397 DISMOUNTING...................................................................................................397 MOUNTING......................................................................................................400 STEERING CONTROL VALVE............................................................................................403 DISMOUNTING...................................................................................................403 MOUNTING......................................................................................................403 STEERING..........................................................................................................404 DISASSEMBLY...................................................................................................404 ASSEMBLY......................................................................................................404 STEERING MAIN RELIEF VALVE........................................................................................406 DISASSEMBLY...................................................................................................406 ASSEMBLY......................................................................................................406 MAIN CLUTCH AND STEERING PUMP (D50)...............................................................................408 DISMOUNTING...................................................................................................408 MOUNTING......................................................................................................408 TRANSMISSION PUMP (D53)...........................................................................................409 DISMOUNTING...................................................................................................409 MOUNTING......................................................................................................411 STEERING PUMP (D53)...............................................................................................413 DISMOUNTING...................................................................................................413 MOUNTING......................................................................................................413 FINAL DRIVE FIRST PINION..........................................................................................414 DISMOUNTING...................................................................................................414 MOUNTING......................................................................................................416 FINAL DRIVE.......................................................................................................418 DISASSEMBLY...................................................................................................418 ASSEMBLY......................................................................................................424 24 MAINTENANCE STANDARD...............................................................................................434 MAIN CLUTCH.......................................................................................................435 TRANSMISSION......................................................................................................440 DAMPER AND UNIVERSAL JOINT........................................................................................444 TORQUE CONVERTER..................................................................................................445 TORQFLOW TRANSMISSION (SERIAL NO.80001-81637).....................................................................449 TRANSMISSION CONTROL VALVE (SERIAL NO.80001-81637)................................................................451 TORQFLOW TRANSMISSION (SERIAL NO.81638 AND UP)....................................................................453 TRANSMISSION CONTROL VALVE (SERIAL NO.81638 AND UP)...............................................................455 TRANSMISSION LUBRICATING VALVE....................................................................................457 TRANSMISSION PUMP.................................................................................................458 BEVEL GEAR SHAFT AND STEERING SYSTEM..............................................................................459 STEERING CONTROL VALVE............................................................................................461 RELIEF VALVE......................................................................................................463 STEERING PUMP.....................................................................................................464 STEERING BRAKE....................................................................................................465 FINAL DRIVE.......................................................................................................467 30 UNDERCARRIAGE..........................................................................................................470 31 STRUCTURE AND FUNCTION.............................................................................................470 TRACK GROUP.......................................................................................................471 RECOIL SPRING.....................................................................................................473 IDLER.............................................................................................................474 CARRIER ROLLER....................................................................................................475 TRACK ROLLER......................................................................................................476 TRACK.............................................................................................................477 SUSPENSION........................................................................................................481 33 DISASSEMBLY AND ASSEMBLY...........................................................................................482 TRACK FRAME.......................................................................................................483 DISMOUNTING...................................................................................................483 MOUNTING......................................................................................................485 RECOIL SPRING.....................................................................................................487 DISMOUNTING...................................................................................................487 MOUNTING......................................................................................................491 FRONT IDLER.......................................................................................................495 DISMOUNTING...................................................................................................495 MOUNTING......................................................................................................496 TRACK ROLLER......................................................................................................497 DISMOUNTING...................................................................................................497 MOUNTING......................................................................................................498 DISASSEMBLY...................................................................................................499 ASSEMBLY......................................................................................................501 CARRIER ROLLER....................................................................................................505 DISMOUNTING...................................................................................................505 MOUNTING......................................................................................................505 TRACK SHOE........................................................................................................506 DISMOUNTING...................................................................................................506 MOUNTING......................................................................................................508 ADJUSTING.....................................................................................................510 34 MAINTENANCE STANDARD...............................................................................................511 TRACK FRAME.......................................................................................................512 RECOIL SPRING.....................................................................................................513 IDLER.............................................................................................................514 TRACK ROLLER......................................................................................................516 CARRIER ROLLER....................................................................................................518 MEASURING PROCEDURE OF ROLLERS....................................................................................520 TRACK.............................................................................................................522 SUSPENSION........................................................................................................532 60 HYDRAULIC SYSTEM.......................................................................................................533 61 STRUCTURE AND FUNCTION.............................................................................................533 HYDRAULIC OIL PIPING FOR BLADE LIFT...............................................................................534 HYDRAULIC OIL PIPING FOR BLADE TILT...............................................................................535 RIPPER PIPING AND CONTROL LINKAGE.................................................................................536 HYDRAULIC PUMP....................................................................................................537 HYDRAULIC CONTROL SYSTEM..........................................................................................538 ANGLEDOZER....................................................................................................538 ANGLEDOZER WITH RIPPER........................................................................................540 STRAIGHT-TILTDOZER............................................................................................542 STRAIGHT-TILTDOZER WITH RIPPER................................................................................544 BLADE CONTROL.....................................................................................................546 HYDRAULIC TANK....................................................................................................548 BLADE LIFT CONTROL VALVE..........................................................................................550 BLADE LIFT AND TILT CONTROL VALVE.................................................................................551 MAIN RELIEF VALVE.................................................................................................552 SUCTION VALVE.....................................................................................................553 RIPPER CONTROL VALVE..............................................................................................554 WORK EQUIPMENT CYLINDER...........................................................................................556 62 TESTING AND ADJUSTING..............................................................................................559 STANDARDS FOR TESTING AND ADJUSTING...............................................................................560 MEASUREMENT LOCATIONS FOR HYDRAULIC OIL PRESSURE..................................................................564 HYDRAULIC OIL PRESSURE ADJUSTMENT.................................................................................564 BLEEDING AIR FROM HYDRAULIC CYLINDERS.............................................................................565 TROUBLESHOOTING...................................................................................................566 PREPARATION FOR TROUBLESHOOTING...............................................................................566 HOW TO USE DIAGNOSTIC TABLES..................................................................................568 PREVENTING RECURRENCE OF THE SAME TROUBLE.....................................................................570 DIAGNOSTIC TABLES.............................................................................................571 1.INSUFFICIENT RAISING POWER AND RAISING SPEED OF BLADE...................................................571 2.BLADE FAILS TO BE RAISED................................................................................572 3.BLADE CANNOT LIFT THE MACHINE BODY......................................................................573 4.EXCESSIVE HYDRAULIC DRIFT OF BLADE......................................................................574 5.THE BLADE FLUCTUATES UP AND DOWN IN LEVELING WORK (WITH CONTROL LEVER IN HOLD POSITION).................575 6.THE BLADE LOWERS........................................................................................575 7.THE BLADE IS RAISED UNEVENLY (APPLICABLE ONLY TO STRAIGHT DOZER)........................................575 8.INSUFFICIENT TILTING POWER AND TILTING SPEED, OR INABILITY TO RAISE THE MACHINE BODY WITH TILT DOZER....576 9.THE BLADE FAILS TO TILT.................................................................................577 10.EXCESSIVE HYDRAULIC DRIFT TO TILTED BLADE..............................................................578 63 DISASSEMBLY AND ASSEMBLY...........................................................................................579 HYDRAULIC PUMP (D50)..............................................................................................580 DISMOUNTING...................................................................................................580 MOUNTING......................................................................................................580 HYDRAULIC PUMP (D53)..............................................................................................581 DISMOUNTING...................................................................................................581 MOUNTING......................................................................................................582 WORK EQUIPMENT CONTROL VALVE......................................................................................583 DISMOUNTING...................................................................................................583 MOUNTING......................................................................................................585 WORK EQUIPMENT CONTROL VALVE......................................................................................587 DISASSEMBLY...................................................................................................587 ASSEMBLY......................................................................................................587 LIFT CYLINDER.....................................................................................................591 DISMOUNTING...................................................................................................591 MOUNTING......................................................................................................591 CYLINDER..........................................................................................................592 DISASSEMBLY...................................................................................................592 ASSEMBLY......................................................................................................596 64 MAINTENANCE STANDARD...............................................................................................600 HYDRAULIC CONTROL VALVE...........................................................................................601 CYLINDER..........................................................................................................605 HYDRAULIC PUMP....................................................................................................608 70 WORK EQUIPMENT.........................................................................................................609 71 STRUCTURE AND FUNCTION.............................................................................................609 ANGLEDOZER........................................................................................................610 STRAIGHT-TILTDOZER................................................................................................611 RIPPER............................................................................................................612 73 DISASSEMBLY AND ASSEMBLY...........................................................................................613 WORK EQUIPMENT....................................................................................................614 DISMOUNTING...................................................................................................614 MOUNTING......................................................................................................615 STRAIGHT-TILT DOZER...............................................................................................616 INSTALLATION AND ADJUSTMENT...................................................................................616 DASHBOAD..........................................................................................................618 DISMOUNTING...................................................................................................618 MOUNTING......................................................................................................621 OPERATOR'S SEAT AND FRAME (D50)...................................................................................624 DISMOUNTING...................................................................................................624 MOUNTING......................................................................................................627 OPERATOR'S SEAT AND FRAME (D53)...................................................................................630 DISMOUNTING...................................................................................................630 MOUNTING......................................................................................................633 74 MAINTENANCE STANDARD...............................................................................................636 ANGLEDOZER........................................................................................................637 STRAIGHT-TILTDOZER................................................................................................640 RIPPER............................................................................................................643 80 ELECTRICAL SYSTEM......................................................................................................645 81 STRUCTURE AND FUNCTION.............................................................................................645 ELECTRICAL WIRING DIAGRAM.........................................................................................646 ELECTRICAL CIRCUIT DIAGRAM........................................................................................647 82 TESTING AND ADJUSTING..............................................................................................648 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE).....................................................................649 E-1 ENGINE DOES NOT START.....................................................................................650
KOMATSU D50A-17, D50P-17, D53A-17, D53P-17 CRAWLER BULLDOZER SHOP MANUAL SEBM01301707 – PDF DOWNLOAD:
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