Komatsu D575A-2 Shop Manual SEBM000105 – PDF DOWNLOAD

Description

Komatsu D575A-2 Crawler Tractor Shop Manual SEBM000105 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D575A-2 Crawler Tractor Shop Manual SEBM000105 – PDF DOWNLOAD

Language : English
Pages : 650
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Komatsu D575A-2 Crawler Tractor Shop Manual SEBM000105 – PDF DOWNLOAD

MACHINE MODEL  SERIAL NUMBER
 D575A-2                  10001 and up

MAIN MENU 0
CONTENTS 2
01 GENERAL 21
SPECIFICATIONS 22
WEIGHT TABLE 26
FUEL, COOLANT AND LUBRICANTS 28
10 STRUCTURE AND FUNCTION 30
RADIATOR, OIL COOLER 31
FUEL PIPING DRAWING 33
ENGINE CONTROL 34
ENGINE CONTROL HYDRAULIC BOOSTER 35
POWER TRAIN SYSTEM 40
POWER TRAIN SKELTON 41
POWER TRAIN HYDRAULIC PIPING 42
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 44
POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS (Engine running transmission shift lever in “NEUTRAL”, steering levers and brake pedal not operated) 45
DAMPER 46
TORQUE CONVERTER, PTO 47
TORQUE CONVERTER FILTER, TORQUE CONVERTER RELIEF VALVE 51
TRANSMISSION CONTROL 52
TRANSMISSION 53
POWER TRAIN 56
TRANSMISSION CONTROL VALVE 59
PILOT REDUCING VALVE 61
PRIORITY VALVE 62
MODULATING VALVE 63
REDUCING VALVE 66
TRANSMISSION LUBRICATION VALVE 67
SPEED, DIRECTIONAL SELECTOR VALVE 68
STEERING CLUTCH, BRAKE CONTROL 73
STEERING CLUTCH, BRAKE CONTROL CIRCUIT DIAGRAM 74
STEERING CLUTCH, BRAKE CONTROL CIRCUIT SCHEMATICS 75
STEERING CONTROL VALVE 76
STEERING CLUTCH, STEERING BRAKE 82
FINAL DRIVE 86
LUBRICATION PUMP 89
LUBRICATION VALVE 90
TRACK FRAME 91
RECOIL SPRING 93
HYDRAULIC ASSIST RETURN VALVE 94
TRACK ROLLER BOGIE 95
SUSPENSION 96
HYDRAULIC PIPING DIAGRAM FOR COOLING FAN DRIVE AND WORK EQUIPMENT 98
COOLING FAN DRIVE SYSTEM 98
BLADE SYSTEM 99
RIPPER SYSTEM 100
WORK EQUIPMENT CONTROL, ENGINE CONTROL BOOSTER SYSTEM 101
CENTRALIZED OIL PRESSURE DETECTION PIPING DIAGRAM 102
HYDRAULIC CIRCUIT DIAGRAM FOR COOLING FAN DRIVE AND WORK EQUIPMENT 103
HYDRAULIC CIRCUIT SCHMATICS FOR COOLING FAN DRIVE AND WORK EQUIPMENT (Engine running, work equipment control lever in 104
HYDRAULIC TANK 105
ACCUMULATOR (For work equipment circuit) 106
COOLING FAN DRIVE CIRCUIT SCHEMATICS (Engine running) 107
MAIN RELIEF VALVE FOR COOLING FAN DRIVE 108
PPC VALVE 109
FOR BLADE 109
FOR RIPPER 111
ACCUMULATOR (For PPC circuit) 115
PPC RELIEF VALVE 116
PPC SHUTTLE VALVE 117
MAIN CONTROL VALVE 118
BLADE VALVE 118
RIPPER VALVE 120
RIPPER BYPASS VALVE 125
DUAL TILT SOLENOID VALVE 126
PISTON VALVE 127
QUICK DROP VALVE 128
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT 129
PIN-PULLER HYDRAULIC CIRCUIT SCHEMATICS (Engine running, Pin-puller switch is at “HOLD”) 135
PIN-PULLER HYDRAULIC CIRCUIT DIAGRAM 135
PIN-PULLER SOLENOID VALVE 136
PIN-PULLER SWITCH 138
PIN-PULLER CYLINDER 139
CYLINDER STAY 140
U-DOZER (K-link type) 141
VARIABLE GIANT RIPPER 143
ELECTRIC CIRCUIT DIAGRAM 145
ELECTRIC CIRCUIT DIAGRAM INSIDE CAB 146
EVMS 147
MONITOR PANEL 148
SENSOR 150
RADIATOR WATER LEVEL SENSOR 150
FUEL LEVEL SENSOR 151
HYDRAULIC OIL TEMPERATURE SENSOR 152
ENGINE OIL PRESSURE SENSOR 152
ENGINE WATER TEMPERATURE, TORQUE CONVERTER OIL TEMPERATURE SENSOR 153
ENGINE OIL LEVEL SENSOR 153
20 TESTING AND ADJUSTING 154
STANDARD VALUE TABLE FOR ENGINE 155
STANDARD VALUE TABLE FOR CHASSIS 156
STANDARD VALUE TABLE FOR ELECTRIC SYSTEM 162
TABLE OF TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 164
ADJUSTING VALVE CLEARANCE 165
MEASURING COMPRESSION PRESSURE 166
TESTING AND ADJUSTING FUEL INJECTION TIMING 167
ADJUSTING FUEL INJECTION PUMP RACK LINKAGE 169
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 170
MEASURING EXHAUST TEMPERATURE 171
MEASURING BLOWBY 172
MEASURING COOLING FAN SPEED 173
MEASURING TORQUE CONVERTER STALL SPEED 174
MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (Full stall) 175
MEASURING, ADJUSTING FAN PUMP RELIEF PRESSURE 176
MEASURING FAN PUMP DISCHARGE AMOUNT 177
MEASURING FAN MOTOR DRAIN AMOUNT 177
MEASURING POWER TRAIN OIL PRESSURE 178
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE 181
PROCEDURE FOR RELEASING STEERING BRAKE 181
TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE (Main relief pressure) AND PPC CIRCUIT PRESSURE 182
WORK EQUIPMENT CIRCUIT 183
PPC CIRCUIT 184
MEASURING PPC VALVE OUTPUT PRESSURE 185
ADJUSTING WORK EQUIPMENT, PPC VALVE 186
RELEASING AIR REMAINING IN HYDRAULIC CIRCUIT ON MACHINES EQUIPPED WITH PPC VALVE 187
BLEEDING AIR FROM HYDRAULIC CYLINDER 187
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER 188
MEASURING PIN-PULLER SOLENOID VALVE OUTPUT PRESSURE 189
ADJUSTING FUEL CONTROL LINKAGE 190
ADJUSTMENT OF GEARSHIFT LEVER LINKAGE 192
ADJUSTMENT OF STEERING LEVER LINKAGE 194
ADJUSTMENT OF BRAKE PEDAL LINKAGE 196
PROCEDURE FOR TESTING SENSORS 198
TROUBLESHOOTING 200
POINTS TO REMEMBER WHEN TROUBLESHOOTING 201
SEQUENCE OF EVENTS IN TROUBLESHOOTING 202
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE 203
HANDLING CONNECTORS 210
CHECKS BEFORE TROUBLESHOOTING 211
METHOD OF MATRIX TROUBLESHOOTING CHART 212
METHOD OF USING TROUBLESHOOTING CHARTS 216
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 218
LOCATION OF CONNECTOR, SENSOR 220
CONNECTION TABLE FOR CONNECTOR 221
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM 226
STARTING CIRCUIT 226
RIPPER PIN-PULLER, DUAL TILT SOLENOID SYSTEM 227
MONITOR SYSTEM 228
TROUBLESHOOTING OF ENGINE SYSTEM 229
S-1 Starting performance is poor 230
S-2 Engine does not start 231
(1) Engine does not turn 231
(2) Engine turns but no exhaust smoke comes out 232
(3) Exhaust smoke comes out but engine does not start 233
S-3 Engine does not pick up smoothly 234
S-4 Engine stops during operations 235
S-5 Engine does not rotate smoothly 236
S-6 Engine lacks output (No power) 237
S-7 Exhaust smoke is black 238
S-8 Oil consumption is excessive 239
S-9 Oil becomes contaminated quickly 240
S-10 Fuel consumption is excessive 241
S-11 Oil is in cooling water, or water spurts back, or water level goes down 242
S-12 Oil pressure lamp lights up 243
S-13 Oil level rises 244
S-14 Water temperature becomes too high 245
S-15 Abnormal noise is made 246
S-16 Vibration is excessive 247
TROUBLESHOOTING OF ELECTRIC, HYDRAULIC, MECHANICAL SYSTEM 248
TABLE OF FAILURE MODES AND CAUSES 249
TROUBLESHOOTING OF ELECTRICAL SYSTEM 250
E-1 Engine doesn’t start 251
E-2 Dual tilt cannot be used (Pitch can be used) 254
E-3 Pitch dozer cannot be used (Dual tilt can be used) 255
E-4 Neither dual tilt nor pitch dozer can be used 256
E-5 Pin-puller cylinder does not work 257
a) Pin cannot be removed 257
b) Pin cannot be inserted 258
E-6 Head lamps do not light up 259
a) Left head lamp does not light up 259
b) Right head lamp does not light up 259
E-7 Rear lamps do not light up 260
E-8 Working lamp does not light up 261
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM 263
H-1 Brakes do not work 264
H-2 Machine does not turn 265
H-3 There is travel deviation 266
H-4 Machine turns only in one direction (Lever operated) 267
H-5 Time lag is excessive 268
H-6 Machine travels only in one direction (Forward or in reverse) 270
H-7 Machine does not move (2nd, 3rd) 271
H-8 Machine does not move in any speed range 273
H-9 Torque converter overheats 275
H-10 Abnormal noise from around hydraulic pump 277
H-11 Blade RAISE speed slow or work equipment lacks power 278
H-12 Ripper lift speed slow, or lacks power 279
H-13 Excessive hydraulic drift of blade 280
H-14 Excessive hydraulic drift of ripper 280
H-15 Pin-puller cylinder does not work 281
H-16 Fan speed is slow (Coolant or torque converter overheats) 281
TROUBLESHOOTING MACHINE MONITOR SYSTEM 282
M-1 No display appears on the monitor panel when the starting switch is ON 283
M-2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out 283
M-3 When starting switch is ON (Engine stopped), CHECK items show abnormality 284
a) Abnormality in radiator water level 284
b) Abnormality in engine oil level 285
M-4 When starting switch is ON and engine is started, CAUTION items flash 286
a) Charge level flashes 286
b) Engine oil pressure flashes 286
c) Coolant level flashes 286
d) Coolant temperature flashes 286
e) Torque converter oil temperature flashes 287
f) Hydraulic oil temperature flashes 287
M-5 Abnormality in buzzer 290
a) CAUTION items are flashing, but buzzer does not sound 290
b) No abnormal display is given on monitor, but buzzer sound 290
M-6 Abnormality in gauge 291
a) Abnormality in coolant temperature gauge 291
b) Abnormality in torque converter oil temperature gauge 292
c) Abnormality in fuel level gauge 293
M-7 Service meter does not move after engine is started 294
M-8 Panel lighting for monitor panel does not light up (Liquid crystal display is normal) 295
30 DISASSEMBLY AND ASSEMBLY 296
METHOD OF USING MANUAL 299
PRECAUTIONS WHEN CARRYING OUT OPERATION 301
SPECIAL TOOL LIST 303
STARTING MOTOR 311
REMOVAL 311
INSTALLATION 311
ALTERNATOR 312
REMOVAL 312
INSTALLATION 312
ENGINE OIL COOLER 313
REMOVAL 313
INSTALLATION 314
POWER TRAIN OIL COOLER 315
REMOVAL 315
INSTALLATION 317
HYDRAULIC COOLER 318
REMOVAL 318
INSTALLATION 318
FUEL INJECTION PUMP (Left and right) 319
REMOVAL 319
INSTALLATION 322
WATER PUMP 323
REMOVAL 323
INSTALLATION 323
TURBOCHARGER 324
REMOVAL 324
INSTALLATION 324
AFTER-COOLER CORE 326
REMOVAL 326
INSTALLATION 326
NOZZLE HOLDER 327
REMOVAL 327
INSTALLATION 327
CYLINDER HEAD 328
REMOVAL 328
INSTALLATION 332
RADIATOR 334
REMOVAL 334
INSTALLATION 335
FAN MOTOR 336
REMOVAL 336
INSTALLATION 338
ENGINE 339
REMOVAL 339
INSTALLATION 344
DAMPER 345
REMOVAL 345
INSTALLATION 346
DISASSEMBLY 347
ASSEMBLY 348
POWER TRAIN 350
REMOVAL 350
INSTALLATION 354
PTO, TORQUE CONVERTER 356
REMOVAL 356
INSTALLATION 359
DISCONNECTION 360
CONNECTION 361
PTO 362
DISASSEMBLY 362
ASSEMBLY 367
TORQUE CONVERTER 373
DISASSEMBLY 373
ASSEMBLY 377
TORQFLOW TRANSMISSION 381
REMOVAL 381
INSTALLATION 382
DISASSEMBLY 383
ASSEMBLY 395
STEERING, LUBRICATION PUMP 409
REMOVAL 409
INSTALLATION 409
STEERING CASE 410
REMOVAL 410
INSTALLATION 411
DISASSEMBLY 412
ASSEMBLY 418
STEERING CLUTCH 427
DISASSEMBLY 427
ASSEMBLY 429
STEERING BRAKE 433
DISASSEMBLY 430
ASSEMBLY 433
TRANSMISSION CONTROL VALVE 438
REMOVAL 438
INSTALLATION 438
DISASSEMBLY 439
ASSEMBLY 439
STEERING CONTROL VALVE 444
REMOVAL 444
INSTALLATION 444
DISASSEMBLY 445
ASSEMBLY 445
POWER TRAIN 447
REMOVAL 447
INSTALLATION 447
TRANSMISSION LUBRICATION PUMP 448
REMOVAL 448
INSTALLATION 448
SCAVENGING PUMP 449
REMOVAL 449
INSTALLATION 449
FINAL DRIVE 450
REMOVAL 450
INSTALLATION 450
DISASSEMBLY 451
ASSEMBLY 461
TRACK FRAME 474
REMOVAL 474
INSTALLATION 476
HYDRAULIC ASSIST, RECOIL SPRING 477
REMOVAL 477
INSTALLATION 478
DISASSEMBLY 479
ASSEMBLY 485
IDLER 492
REMOVAL 490
INSTALLATION 491
DISASSEMBLY 492
ASSEMBLY 494
TRACK ROLLER 496
REMOVAL 496
INSTALLATION 498
DISASSEMBLY 499
ASSEMBLY 501
BOGIE 503
REMOVAL 503
INSTALLATION 503
DISASSEMBLY 504
ASSEMBLY 507
CARRIER ROLLER 510
REMOVAL 510
INSTALLATION 510
DISASSEMBLY 511
ASSEMBLY 513
TRACK SHOE 516
CHECKING 516
REMOVAL 516
INSTALLATION 520
OVERALL DISASSEMBLY 521
OVERALL ASSEMBLY 526
PRESS FITTING JIG DIMENSION TABLE FOR LINK PRESS 540
FIELD DISASSEMBLY OF ONE LINK 541
FIELD ASSEMBLY OF ONE LINK 543
DISASSEMBLY OF MASTER LINK 545
ASSEMBLY OF MASTER LINK 547
PIVOT SHAFT 551
REMOVAL 551
INSTALLATION 552
EQUALIZER BAR 553
REMOVAL 553
INSTALLATION 555
HYDRAULIC, PPC PUMP 558
REMOVAL 558
INSTALLATION 558
FAN, HYDRAULIC PUMP 559
REMOVAL 559
INSTALLATION 559
BLADE VALVE 560
REMOVAL 560
INSTALLATION 560
DISASSEMBLY 562
ASSEMBLY 562
RIPPER VALVE 564
REMOVAL 564
INSTALLATION 564
DISASSEMBLY 565
ASSEMBLY 565
MAIN RELIEF VALVE 567
DISASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY 567
ASSEMBLY OF MAIN RELIEF VALVE ASSEMBLY 567
BLADE LIFT CYLINDER 568
REMOVAL 568
INSTALLATION 568
BLADE TILT CYLINDER 569
REMOVAL 569
INSTALLATION 569
RIPPER LIFT CYLINDER 570
REMOVAL 570
INSTALLATION 570
RIPPER TILT CYLINDER 571
REMOVAL 571
INSTALLATION 571
HYDRAULIC CYLINDER 572
DISASSEMBLY 572
ASSEMBLY 575
PIN-PULLER CYLINDER 578
REMOVAL 578
INSTALLATION 578
DISASSEMBLY 579
ASSEMBLY 580
BLADE PPC VALVE 582
REMOVAL 582
INSTALLATION 582
DISASSEMBLY 583
ASSEMBLY 583
RIPPER PPC VALVE 585
REMOVAL 585
INSTALLATION 585
DISASSEMBLY 586
ASSEMBLY 586
BLADE (K-link type) 587
REMOVAL 587
INSTALLATION 588
DISASSEMBLY 589
ASSEMBLY 591
VARIABLE GIANT RIPPER 594
DISASSEMBLY 594
ASSEMBLY 597
OPERATOR’S SEAT FRAME 600
REMOVAL 600
INSTALLATION 602
CAB 603
REMOVAL 603
INSTALLATION 604
ROPS 605
REMOVAL 605
INSTALLATION 605
40 MAINTENANCE STANDARD 606
ENGINE MOUNT 607
DAMPER 608
TORQUE CONVERTER, PTO 609
TRANSMISSION 611
TRANSMISSION CONTROL VALVE 613
SPEED, DIRECTIONAL SELECTOR VALVE 615
STEERING CONTROL VALVE 616
STEERING CLUTCH, STEERING BRAKE 618
FINAL DRIVE 621
TRACK FRAME 623
RECOIL SPRING 625
HYDRAULIC ASSIST RETURN VALVE 626
IDLER 627
TRACK ROLLER BOGIE 628
TRACK ROLLER 629
TRACK SHOE (Lubricated track link) 631
SUSPENSION 633
HYDRAULIC PUMP 634
SAL(4)-140+125 634
SAR(4)-250 635
SAL(4)-200+160 636
SAR(4)-125+125+(1)-32 637
WORK EQUIPMENT CYLINDER 639
PIN PULLER CYLINDER 642
CYLINDER STAY 643
U-DOZER (K-link type) 645
CUTTING EDGES AND END BITS 647
VARIABLE GIANT RIPPER 648

DESCRIPTION:

Komatsu D575A-2 Crawler Tractor Shop Manual SEBM000105 – PDF DOWNLOAD

MACHINE MODEL  SERIAL NUMBER
 D575A-2                  10001 and up

G.B  14/12/24