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KOMATSU D575A-2 SUPER DOZER SHOP MANUAL SEBM018506 – PDF DOWNLOAD
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Description
KOMATSU D575A-2 SUPER DOZER SHOP MANUAL SEBM018506 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D575A-2 SUPER DOZER SHOP MANUAL SEBM018506 – PDF DOWNLOAD
Language : English
Pages : 812
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D575A-2 SUPER DOZER SHOP MANUAL SEBM018506 – PDF DOWNLOAD
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 FRAME.....................................................................................................................................102 RECOIL SPRING...................................................................................................................................104 TRACK ROLLER BOGIE..............................................................................................................................105 SUSPENSION......................................................................................................................................106 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 EQUIPMENT....................................................................................................113 HYDRAULIC TANK .................................................................................................................................114 ACCUMULATOR FOR WORK EQUIPMENT CIRCUIT..........................................................................................................115 PITCH, TILT SELECTOR SOLENOID VALVE ASSEMBLY ...................................................................................................116 PITCH BACK (PITCH DUMP) SOLENOID VALVE .........................................................................................................117 PPC VALVE ......................................................................................................................................119 ACCUMULATOR FOR PPC CIRCUIT.....................................................................................................................123 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 CIRCUIT.....................................................................................................135 CYLINDER STAY, YOKE.............................................................................................................................143 WORK EQUIPMENT .................................................................................................................................145 COUNTERWEIGHT...................................................................................................................................147 CAB ............................................................................................................................................148 AIR CONDITIONER.................................................................................................................................150 ACTUAL ELECTRIC WIRING DIAGRAM..................................................................................................................152 ELECTRICAL CIRCUIT DIAGRAM .....................................................................................................................154 EVMS (Electronic Vehicle Monitoring System) ....................................................................................................158 TORQUE CONVERTER LOCK-UP, BLADE CONTROL SYSTEM .................................................................................................170 20 TESTING AND ADJUSTING............................................................................................................................178 STANDARD VALUE TABLE FOR ENGINE.................................................................................................................179 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 PRESSURE..............................................................................................................209 PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE.........................................................................................213 PROCEDURE FOR RELEASING STEERING BREAK..........................................................................................................213 TESTING AND ADJUSTING WORK EQUIPMENT CIRCUIT PRESSURE (MAIN RELIEF AND PPC CIRCUIT) ............................................................214 MEASURING PPC VALVE OUTPUT PRESSURE.............................................................................................................217 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 BLADE..........................................................................................220 MEASURING LEAKAGE INSIDE CYLINDER...............................................................................................................221 ADJUSTING FUEL CONTROL LINKAGE .................................................................................................................222 ADJUSTMENT OF GEARSHIFT LEVER LINKAGE ..........................................................................................................225 ADJUSTMENT OF STEERING LEVER LINKAGE............................................................................................................227 ADJUSTMENT OF BRAKE PEDAL LINKAGE ..............................................................................................................229 PROCEDURE FOR TESTING SENSORS ..................................................................................................................231 TROUBLESHOOTING.................................................................................................................................233 POINTS TO REMEMBER WHEN TROUBLESHOOTING ....................................................................................................234 SEQUENCE OF EVENTS IN TROUBLESHOOTING ......................................................................................................235 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................................................236 CHECKS BEFORE TROUBLESHOOTING ..............................................................................................................244 METHOD OF USING TROUBLESHOOTING CHARTS .....................................................................................................245 TYPE OF CONNECTOR AND POSITION OF INSTALLATION .............................................................................................251 LOCATION OF CONNECTOR, SENSOR...............................................................................................................255 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 start..............................................................................................................271 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 up.........................................................................................................277 a) Left head lamp does not light up.................................................................................................277 b) Right head lamp does not light up................................................................................................277 E-8. Rear lamps do not light up.........................................................................................................278 E-9. Working lamp does not light up.....................................................................................................278 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)...................................................................................................280 S-1 Starting performance is poor (Starting always takes time)...........................................................................281 S-2 Engine does not start...............................................................................................................282 (1) Engine does not turn............................................................................................................282 (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 operations......................................................................................................286 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 quickly....................................................................................................291 S-10 Fuel consumption is. excessive.....................................................................................................292 S-11 Oil is in cooling water, or water spurts back, or water level goes down............................................................293 S-12 Oil pressure caution lamp lights up (Drop in oil pressure).........................................................................294 S-13 Oil level rises....................................................................................................................295 S-14 Water temperature becomes too high (Overheating)...................................................................................296 S-15 Abnormal noise is made.............................................................................................................297 S-16 Vibration is excessive.............................................................................................................298 TROUBLESHOOTING OF WORK EQUIPMENT, LOCK-UP CONTROLLER SYSTEM (E MODE).......................................................................299 MONITOR PANEL, CONTROLLER DISPLAY METHOD................................................................................................300 ACTION TAKEN BY CONTROLLER WHEN ABNORMALITY OCCURS AND PROBLEMS ON MACHINE..............................................................308 ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT, LOCK-UP CONTROLLER SYSTEM................................................................316 E-101 [01] Oil Drop in controller power source voltage..............................................................................317 E-102 [02] Incorrect standard value for yoke angle..................................................................................318 E-103 [03] Transmission slips.......................................................................................................319 E-104 [04] Engine overrun...........................................................................................................319 E-105 [10, 11,12] Engine speed sensor system........................................................................................320 E-106 [1A, 1C] Bevel gear speed sensor system.......................................................................................322 E-107 [20,21] Left yoke angle sensor system.........................................................................................324 E-108 [22,23] Right yoke angle sensor system........................................................................................326 E-109 [30] Blade lift oil pressure switch system....................................................................................328 E-110 [31] Pitch dump switch system.................................................................................................329 E-111 [32] Pitch back switch system.................................................................................................331 E-112 [40,41] Transmission F (FORWARD) oil pressure switch system...................................................................333 E-113 [40,42] Transmission R (REVERSE) oil pressure switch system...................................................................335 E-114 [45,46] Transmission 1 (1st) oil pressure switch system.......................................................................337 E-115 [45,47] Transmission 2 (2nd) oil pressure switch system.......................................................................339 E-116 [45,46] Transmission 3 (3rd) oil pressure switch system.......................................................................341 E-117 [4A, 4C, 4E] Transmission modulating oil pressure switch system...............................................................343 E-118 [60,61] Pitch dump solenoid system............................................................................................345 E-119 [62,63] Pitch back solenoid system............................................................................................347 E-120 [64,65] Pitch selector solenoid system........................................................................................349 E-121 [66,67] Left tilt limit solenoid system.......................................................................................350 E-122 [68, 69] Right tilt limit solenoid system.....................................................................................351 E-123 [6A, 6C] Pitch priority solenoid system.......................................................................................352 E-124 [6E, 6F] Pitch assist pump relay system.......................................................................................353 E-125 [70,71] Lock-up solenoid system...............................................................................................355 E-126 [80,81] Alarm buzzer system...................................................................................................357 E-127 [8A] System abnormality lamp system...........................................................................................360 E-128 [8C] Lock-up lamp display lamp system.........................................................................................361 E-129 [F0] Monitor caution lamp system..............................................................................................362 E-130 [F1] Buzzer cancel switch system..............................................................................................364 E-131 Lock-up switch system.........................................................................................................365 E-132 Pitch assist pump solenoid (left) system......................................................................................366 E-133 Pitch assist pump solenoid (right) system.....................................................................................367 TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE).....................................................................................368 TABLE OF FAILURE MODES AND CAUSES (ELECTRIC, HYDRAULIC, MECHANICAL SYSTEMS).............................................................369 H-1. Brakes do not work.............................................................................................................371 H-2. Machine does not turn. (Machine can travel only in a straight line.)...........................................................372 H-3. There is travel deviation......................................................................................................373 H-4. Machine turns only in one direction (Lever operated)...........................................................................374 H-5. Time lag is excessive..........................................................................................................375 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 range.......................................................................................380 H-9. Torque converter overheats.....................................................................................................382 H-10. Abnormal noise from around hydraulic pump.....................................................................................384 H-11. Blade RAISE speed slow or work equipment lacks power..........................................................................385 H-12. Blade pitch speed slow or blade pitch lacks power.............................................................................386 H-13. Excessive hydraulic drift of blade............................................................................................387 H-14. Excessive hydraulic drift of blade pitch......................................................................................387 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)..........................................................................................388 TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR).....................................................................................389 ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM...........................................................................................391 M-1 No display appears on the monitor panel when the starting switch is ON..........................................................392 M-2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out............................................392 M-3 When starting switch is ON (Engine stopped), CHECK items show abnormality (The radiator and engine oil level in the CHECK it....393 a) Abnormality in radiator water level monitor..................................................................................393 b) Abnormality in engine oil level monitor......................................................................................394 M-4 When starting switch is ON and engine is started, CAUTION items flash...........................................................395 a) Charge level monitor flashes.................................................................................................395 b) Engine oil pressure monitor flashes..........................................................................................395 c) Coolant level monitor flashes................................................................................................395 d) Coolant temperature monitor flashes..........................................................................................395 e) Torque converter oil temperature monitor flashes.............................................................................396 f) Hydraulic oil temperature monitor flashes....................................................................................396 M-5 Abnormality in buzzer...........................................................................................................399 a) CAUTION items are flashing, but buzzer does not sound........................................................................399 b) Monitor panel does not display any abnormality, but buzzer sounds............................................................399 M-6 Abnormality in gauge............................................................................................................401 a) Abnormality in coolant temperature gauge.....................................................................................401 b) Abnormality in torque converter oil temperature gauge........................................................................402 c) Fuel gauge always displays FULL..............................................................................................403 M-7 Service meter does not move after engine is started.............................................................................404 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 ASSEMBLY.........................................................................................................................407 METHOD OF USING MANUAL..........................................................................................................................409 PRECAUTIONS WHEN CARRYING OUT OPERATION.........................................................................................................411 SPECIAL TOOL LIST...............................................................................................................................413 STARTING MOTOR..................................................................................................................................426 REMOVAL AND INSTALLATION....................................................................................................................426 ALTERNATOR......................................................................................................................................428 REMOVAL AND INSTALLATION....................................................................................................................428 ENGINE OIL COOLER...............................................................................................................................429 REMOVAL ....................................................................................................................................429 INSTALLATION ...............................................................................................................................430 FUEL INJECTION PUMP.............................................................................................................................431 REMOVAL.....................................................................................................................................431 INSTALLATION................................................................................................................................433 WATER PUMP......................................................................................................................................434 REMOVAL AND INSTALLATION ...................................................................................................................434 TURBOCHARGER....................................................................................................................................435 REMOVAL AND INSTALLATION....................................................................................................................435 AFTER-COOLER CORE...............................................................................................................................437 REMOVAL AND INSTALLATION....................................................................................................................437 NOZZLE HOLDER...................................................................................................................................438 REMOVAL ....................................................................................................................................438 INSTALLATION ...............................................................................................................................439 CYLINDER HEAD...................................................................................................................................440 REMOVAL ....................................................................................................................................440 INSTALLATION ...............................................................................................................................444 POWER TRAIN OIL COOLER..........................................................................................................................446 REMOVAL ....................................................................................................................................446 INSTALLATION................................................................................................................................448 HYDRAULIC COOLER................................................................................................................................449 REMOVAL AND INSTALLATION....................................................................................................................449 RADIATOR........................................................................................................................................450 REMOVAL ....................................................................................................................................450 INSTALLATION ...............................................................................................................................453 FAN DRIVE SUPPORT...............................................................................................................................454 REMOVAL ....................................................................................................................................454 INSTALLATION ...............................................................................................................................456 FAN DRIVE PULLEY................................................................................................................................457 REMOVAL AND INSTALLATION....................................................................................................................457 DISASSEMBLY ................................................................................................................................458 ASSEMBLY ...................................................................................................................................459 REMOVAL ....................................................................................................................................461 INSTALLATION ...............................................................................................................................462 DISASSEMBLY ................................................................................................................................463 ASSEMBLY ...................................................................................................................................464 ENGINE..........................................................................................................................................465 REMOVAL ....................................................................................................................................465 INSTALLATION ...............................................................................................................................468 DAMPER..........................................................................................................................................469 REMOVAL.....................................................................................................................................469 INSTALLATION ...............................................................................................................................470 DISASSEMBLY ................................................................................................................................471 ASSEMBLY ...................................................................................................................................472 POWER TRAIN.....................................................................................................................................474 REMOVAL.....................................................................................................................................474 INSTALLATION ...............................................................................................................................479 PTO, TORQUE CONVERTER...........................................................................................................................481 REMOVAL ....................................................................................................................................481 INSTALLATION ...............................................................................................................................484 DISCONNECTION ..............................................................................................................................485 CONNECTION .................................................................................................................................486 PTO.............................................................................................................................................487 DISASSEMBLY ................................................................................................................................487 ASSEMBLY ...................................................................................................................................492 TORQUE CONVERTER................................................................................................................................498 DISASSEMBLY ................................................................................................................................498 ASSEMBLY ...................................................................................................................................503 TORQFLOW TRANSMISSION...........................................................................................................................510 REMOVAL ....................................................................................................................................510 INSTALLATION ...............................................................................................................................511 DISASSEMBLY ................................................................................................................................512 ASSEMBLY ...................................................................................................................................523 STEERING CASE...................................................................................................................................537 REMOVAL ....................................................................................................................................537 INSTALLATION ...............................................................................................................................538 DISASSEMBLY ................................................................................................................................539 ASSEMBLY ...................................................................................................................................545 STEERING CLUTCH.................................................................................................................................555 DISASSEMBLY ................................................................................................................................555 ASSEMBLY ...................................................................................................................................557 STEERING BRAKE..................................................................................................................................558 DISASSEMBLY ................................................................................................................................558 ASSEMBLY ...................................................................................................................................561 TORQUE CONVERTER VALVE..........................................................................................................................567 REMOVAL AND INSTALLATION....................................................................................................................567 ASSEMBLY ...................................................................................................................................570 DISASSEMBLY ................................................................................................................................568 TRANSMISSION CONTROL VALVE......................................................................................................................572 REMOVAL AND INSTALLATION....................................................................................................................572 DISASSEMBLY AND ASSEMBLY....................................................................................................................573 STEERING CONTROL VALVE..........................................................................................................................582 REMOVAL AND INSTALLATION....................................................................................................................582 DISASSEMBLY ................................................................................................................................583 ASSEMBLY ...................................................................................................................................585 POWER TRAIN PUMP................................................................................................................................587 REMOVAL AND INSTALLATION....................................................................................................................587 TRANSMISSION LUBRICATION PUMP...................................................................................................................588 REMOVAL AND INSTALLATION....................................................................................................................588 SCAVENGING PUMP.................................................................................................................................589 REMOVAL AND INSTALLATION....................................................................................................................589 FINAL DRIVE.....................................................................................................................................590 REMOVAL AND INSTALLATION....................................................................................................................590 DISASSEMBLY ................................................................................................................................591 ASSEMBLY ...................................................................................................................................599 TRACK FRAME.....................................................................................................................................611 REMOVAL ....................................................................................................................................611 INSTALLATION ...............................................................................................................................613 RECOIL SPRING, TUBE.............................................................................................................................614 REMOVAL ....................................................................................................................................614 INSTALLATION ...............................................................................................................................615 DISASSEMBLY ................................................................................................................................616 ASSEMBLY ...................................................................................................................................622 IDLER YOKE, CYLINDER............................................................................................................................625 DISASSEMBLY ................................................................................................................................625 ASSEMBLY ...................................................................................................................................626 IDLER...........................................................................................................................................628 REMOVAL ....................................................................................................................................628 INSTALLATION ...............................................................................................................................629 DISASSEMBLY ................................................................................................................................630 ASSEMBLY ...................................................................................................................................632 TRACK ROLLER....................................................................................................................................635 REMOVAL ....................................................................................................................................635 INSTALLATION................................................................................................................................636 DISASSEMBLY ................................................................................................................................637 ASSEMBLY ...................................................................................................................................639 CARRIER ROLLER..................................................................................................................................641 REMOVAL AND INSTALLATION....................................................................................................................641 DISASSEMBLY ................................................................................................................................642 ASSEMBLY ...................................................................................................................................644 BOGIE...........................................................................................................................................647 REMOVAL.....................................................................................................................................647 INSTALLATION ...............................................................................................................................648 DISASSEMBLY ................................................................................................................................648 ASSEMBLY....................................................................................................................................652 TRACK SHOE......................................................................................................................................655 CHECKING BEFORE REMOVAL.....................................................................................................................655 REMOVAL ....................................................................................................................................655 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)......................................................................................658 INSTALLATION ...............................................................................................................................659 DISASSEMBLY.................................................................................................................................660 ASSEMBLY....................................................................................................................................665 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS................................................................................................680 FIELD DISASSEMBLY OF ONE LINK...................................................................................................................681 DISASSEMBLY.................................................................................................................................681 ASSEMBLY ...................................................................................................................................683 MASTER LINK.....................................................................................................................................685 DISASSEMBLY ................................................................................................................................685 ASSEMBLY ...................................................................................................................................687 ADJUSTING TRACK SHOE TENSION....................................................................................................................690 PIVOT SHAFT.....................................................................................................................................691 REMOVAL ....................................................................................................................................691 INSTALLATION ...............................................................................................................................691 EQUALIZER BAR...................................................................................................................................692 REMOVAL.....................................................................................................................................692 INSTALLATION ...............................................................................................................................694 SEGMENT TEETH...................................................................................................................................697 REMOVAL ....................................................................................................................................697 INSTALLATION ...............................................................................................................................697 WORK EQUIPMENT PUMP.............................................................................................................................698 REMOVAL AND INSTALLATION ...................................................................................................................698 WORK EQUIPMENT ASSIST, CONTROL PUMP.............................................................................................................699 REMOVAL AND INSTALLATION ...................................................................................................................699 BLADE VALVE.....................................................................................................................................700 REMOVAL AND INSTALLATION ...................................................................................................................700 DISASSEMBLY ................................................................................................................................702 ASSEMBLY ...................................................................................................................................704 MAIN RELIEF VALVE...............................................................................................................................706 DISASSEMBLY ................................................................................................................................706 ASSEMBLY ...................................................................................................................................706 BLADE LIFT CYLINDER.............................................................................................................................707 REMOVAL AND INSTALLATION ...................................................................................................................707 BLADE PITCH CYLINDER............................................................................................................................708 REMOVAL AND INSTALLATION ...................................................................................................................708 HYDRAULIC CYLINDER..............................................................................................................................709 DISASSEMBLY.................................................................................................................................709 ASSEMBLY ...................................................................................................................................712 BLADE PPC VALVE.................................................................................................................................715 REMOVAL AND INSTALLATION ...................................................................................................................715 DISASSEMBLY.................................................................................................................................716 ASSEMBLY ...................................................................................................................................716 BLADE...........................................................................................................................................718 REMOVAL ....................................................................................................................................718 INSTALLATION................................................................................................................................719 DISASSEMBLY.................................................................................................................................720 ASSEMBLY....................................................................................................................................722 POTENTIOMETER...................................................................................................................................724 REMOVAL AND INSTALLATION ...................................................................................................................724 OPERATOR’S COMPARTMENT FRAME....................................................................................................................726 REMOVAL ....................................................................................................................................726 INSTALLATION ...............................................................................................................................728 CAB.............................................................................................................................................729 REMOVAL ....................................................................................................................................729 INSTALLATION ...............................................................................................................................730 ROPS............................................................................................................................................731 REMOVAL AND INSTALLATION ...................................................................................................................731 COUNTERWEIGHT. FRAME............................................................................................................................732 REMOVAL AND INSTALLATION ...................................................................................................................732 BLADE LIFT CYLINDER SUPPORT.....................................................................................................................733 REMOVAL ....................................................................................................................................733 INSTALLATION ...............................................................................................................................734 40 MAINTENANCE STANDARD.............................................................................................................................735 ENGINE MOUNT....................................................................................................................................736 DAMPER .........................................................................................................................................737 TORQUE CONVERTER, PTO ..........................................................................................................................738 TORQUE CONVERTER VALVE .........................................................................................................................740 TRANSMISSION....................................................................................................................................742 TRANSMISSION CONTROL VALVE......................................................................................................................744 STEERING CONTROL VALVE..........................................................................................................................748 STEERING CLUTCH, STEERING BRAKE.................................................................................................................750 FINAL DRIVE ....................................................................................................................................754 TRACK FRAME.....................................................................................................................................756 RECOIL SPRING...................................................................................................................................758 IDLER...........................................................................................................................................759 CARRIER ROLLER..................................................................................................................................761 TRACK ROLLER....................................................................................................................................763 TRACK ROLLER BOGIE..............................................................................................................................765 TRACK SHOE .....................................................................................................................................766 SUSPENSION......................................................................................................................................771 HYDRAULIC PUMP..................................................................................................................................773 PPC VALVE.......................................................................................................................................777 MAIN CONTROL VALVE .............................................................................................................................778 WORK EQUIPMENT CYLINDER.........................................................................................................................779 CYLINDER STAY, YOKE ............................................................................................................................781 MAIN FRAME......................................................................................................................................783 WORK EQUIPMENT..................................................................................................................................785 COUNTERWEIGHT ..................................................................................................................................788 90 OTHERS...........................................................................................................................................789 POWER TRAIN HYDRAULIC PIPING....................................................................................................................790 POWER TRAIN HYDRAULIC CIRCUIT SCHEMATICS........................................................................................................791 ENGINE RUNNING, TRANSMISSION SHIFT LEVER IN "NEUTRAL", STEERING LEVERS AND BRAKE PEDAL NOT OPERATED.........................................791 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...........................................................................................................792 TRANSMISSION....................................................................................................................................793 HYDRAULIC PIPING DIAGRAM FOR WORK EQUIPMENT.....................................................................................................794 BLADE SYSTEM................................................................................................................................794 HYDRAULIC CIRCUIT SCHEMATICS FOR WORK EQUIPMENT.................................................................................................795 ENGINE RUNNING, WORK EQUIPMENT CONTROL LEVER IN "HOLD"......................................................................................795 HYDRAULIC CIRCUIT DIAGRAM FOR WORK EQUIPMENT....................................................................................................796 OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT.....................................................................................................797 BLADE RAISE.................................................................................................................................797 BLADE LEFT TILT.............................................................................................................................798 BLADE PITCH BACK............................................................................................................................799 BLADE PITCH DUMP ...........................................................................................................................800 AIR CONDITIONER.................................................................................................................................801 AIR CONDITIONER PIPING......................................................................................................................801 ACTUAL ELECTRICAL WIRING DIAGRAM (1/2)..........................................................................................................802 ACTUAL ELECTRICAL WIRING DIAGRAM (2/2)..........................................................................................................803 ELECTRICAL CIRCUIT DIAGRAM......................................................................................................................806 CHASSIS ELECTRICAL CIRCUIT (1/2)............................................................................................................806 CHASSIS ELECTRICAL CIRCUIT (2/2)............................................................................................................807 AIR CONDITIONER ELECTRICAL CIRCUIT..............................................................................................................808 TORQUE CONVERTER LOCK-UP, BLADE CONTROL SYSTEM..................................................................................................809 LOCATION OF CONNECTOR, SENSOR...................................................................................................................810 ELECTRICAL CIRCUIT DIAGRAM FOR WORK EQUIPMENT, LOCK-UP CONTROLLER SYSTEM........................................................................811 ELECTRICAL CIRCUIT DIAGRAM FOR MONITOR SYSTEM...................................................................................................812
DESCRIPTION:
KOMATSU D575A-2 SUPER DOZER SHOP MANUAL SEBM018506 – PDF DOWNLOAD
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.
S.S 26/12/24
