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KOMATSU D57S-1 SHOP MANUAL SEBM0135A05 – PDF DOWNLOAD
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Description
KOMATSU D57S-1 SHOP MANUAL SEBM0135A05 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D57S-1 SHOP MANUAL SEBM0135A05 – PDF DOWNLOAD
Language : English
Pages : 570
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D57S-1 SHOP MANUAL SEBM0135A05 – PDF DOWNLOAD
COVER........................................................................ 1 CONTENTS..................................................................... 2 10 ENGINE.................................................................... 18 12 TESTING AND ADJUSTING................................................. 18 TESTING AND ADJUSTING................................................ 19 TABLE OF JUDGEMENT STANDARD VALUE................................ 20 TESTING AND ADJUSTING TOOL LIST.................................. 22 ADJUSTING VALVE CLEARANCE........................................ 23 MEASURING COMPRESSION PRESSURE................................... 25 TESTING AND ADJUSTING FUEL INJECTION TIMING (DELIVERY METHOD).... 27 13 DISASSEMBLY AND ASSEMBLY.............................................. 31 DISASSEMBLY AND ASSEMBLY............................................. 32 ALTERNATOR....................................................... 33 DISMOUNTING.................................................. 33 MOUNTING..................................................... 35 STARTING MOTOR................................................... 36 DISMOUNTING.................................................. 36 MOUNTING..................................................... 37 WATER PUMP....................................................... 38 DISMOUNTING.................................................. 38 MOUNTING..................................................... 41 ENGINE OIL COOLER................................................ 44 DISMOUNTING.................................................. 44 MOUNTING..................................................... 46 FUEL INJECTION PUMP.............................................. 48 DISMOUNTING.................................................. 48 MOUNTING..................................................... 50 TURBOCHARGER..................................................... 52 DISMOUNTING.................................................. 52 MOUNTING..................................................... 55 NOZZLE HOLDER AND PRECHAMBER..................................... 58 DISMOUNTING.................................................. 58 MOUNTING..................................................... 62 CYLINDER HEAD.................................................... 66 DISMOUNTING.................................................. 66 MOUNTING..................................................... 74 ENGINE........................................................... 82 DISMOUNTING.................................................. 82 MOUNTING..................................................... 87 RADIATOR......................................................... 92 DISMOUNTING.................................................. 92 RADIATOR GUARD................................................... 96 DISMOUNTING.................................................. 96 RADIATOR......................................................... 99 MOUNTING..................................................... 99 RADIATOR GUARD...................................................103 MOUNTING.....................................................103 ALTERNATOR.......................................................106 REMOVAL......................................................106 INSTALLATION.................................................106 STARTING MOTOR...................................................107 REMOVAL......................................................107 INSTALLATION.................................................107 WATER PUMP.......................................................108 REMOVAL......................................................108 INSTALLATION.................................................108 ENGINE OIL COOLER................................................109 REMOVAL......................................................109 INSTALLATION.................................................109 FUEL INJECTION PUMP..............................................110 REMOVAL......................................................110 INSTALLATION.................................................110 TURBOCHARGER.....................................................111 REMOVAL......................................................111 INSTALLATION.................................................111 CYLINDER HEAD....................................................112 REMOVAL......................................................112 INSTALLATION.................................................113 ENGINE...........................................................114 REMOVAL......................................................114 INSTALLATION.................................................115 NOZZLE HOLDER....................................................116 REMOVAL......................................................116 INSTALLATION.................................................116 20 POWER TRAIN...............................................................117 21 STRUCTURE AND FUNCTION................................................117 STRUCTURE AND FUNCTION...............................................118 GENERAL..........................................................119 POWER TRAIN......................................................120 POWER TRAIN HYDRAULIC SYSTEM.....................................122 POWER TRAIN HYDRAULIC CIRCUIT....................................123 DAMPER AND UNIVERSAL JOINT.......................................124 TORQUE CONVERTER.................................................127 TORQUE CONVERTER RELIEF VALVE....................................130 TORQFLOW TRANSMISSION............................................131 TORQFLOW HYDRAULIC SYSTEM........................................142 TORQFLOW HYDRAULIC CONTROL.......................................144 TORQFLOW HYDRAULIC CIRCUIT.......................................145 TORQFLOW TRANSMISSION CONTROL LINKAGE............................146 TRANSMISSION CONTROL VALVE.......................................148 INCHING VALVE CONTROL LINKAGE....................................154 INCHING VALVE....................................................155 TRANSMISSION LUBRICATING SYSTEM..................................158 TRANSMISSION LUBRICATING VALVE...................................159 TRANSMISSION PUMP................................................160 TRANSMISSION OIL FILTER..........................................161 STEERING HYDRAULIC PIPING........................................162 STEERING CLUTCH HYDRAULIC SYSTEM.................................163 STEERING CLUTCH HYDRAULIC CIRCUIT................................164 BEVEL GEAR SHAFT AND STEERING SYSTEM.............................165 STEERING CONTROL LINKAGE.........................................167 STEERING CONTROL VALVE...........................................169 STEERING CLUTCH..................................................172 STEERING BRAKE...................................................173 STEERING PUMP ...................................................176 STEERING OIL FILTER..............................................177 STEERING OIL STRAINER............................................178 FINAL DRIVE......................................................179 22 TESTING AND ADJUSTING.................................................181 TESTING AND ADJUSTING................................................182 TABLE OF JUDGEMENT STANDARD VALUE................................183 TESTING AND ADJUSTING TOOL LIST..................................185 MEASURING OF OIL PRESSURE AND OIL TEMPERATURE....................186 TESTING AND ADJUSTING FUEL CONTROL LINKAGE.......................189 ADJUSTING GEAR SHIFT LEVER LINKAGE...............................191 TESTING AND ADJUSTING INCHING LINKAGE............................193 TESTING AND ADJUSTING STEERING (BRAKE) LINKAGE...................195 23 DISASSEMBLY AND ASSEMBLY..............................................197 DISASSEMBLY AND ASSEMBLY.............................................198 DISMOUNTING DAMPER (SERIAL NO. 6501-20000).......................201 MOUNTING DAMPER (SERIAL NO. 6501-20000)..........................202 DISMOUNTING DAMPER (SERIAL NO. 20001 AND UP).....................203 MOUNTING DAMPER (SERIAL NO. 20001 AND UP)........................203 DISASSEMBLY OF DAMPER CASE (SERIAL NO. 20001 AND UP).............204 ASSEMBLY OF DAMPER CASE (SERIAL NO. 20001 AND UP)................204 DISMOUNTING TRANSMISSION TORQUE CONVERTER ASSEMBLY...............205 MOUNTING TRANSMISSION TORQUE CONVERTER ASSEMBLY..................213 DISASSEMBLY OF TORQUE CONVERTER PTO ASSEMBLY.....................220 DISASSEMBLY OF TORQUE CONVERTER PUMP ASSEMBLY....................224 DISASSEMBLY OF PTO HOUSING.......................................225 ASSEMBLY OF TORQUE CONVERTER PTO CASE ASSEMBLY...................227 ASSEMBLY OF HYDRAULIC PUMP SHAFT ASSEMBLY].......................228 ASSEMBLY OF PTO HOUSING..........................................229 ASSEMBLY OF TURBINE ASSEMBLY.....................................232 ASSEMBLY OF TORQUE CONVERTER PUMP ASSEMBLY.......................233 ASSEMBLY TORQUE CONVERTER PTO CASE ASSEMBLY......................235 DISMOUNTING TORQUE CONVERTER RELIEF VALVE ASSEMBLY...............239 MOUNTING TORQUE CONVERTER RELIEF VALVE ASSEMBLY..................240 DISCONNECTION OF TRANSMISSION AND TORQUE CONVERTER...............241 DISASSEMBLY OF TRANSMISSION ASSEMBLY.............................242 DISASSEMBLY OF FIRST SPEED CLUTCH................................249 DISASSEMBLY OF NO. 2 HOUSING FR CARRIER ASSEMBLY.................253 DISASSEMBLY OF INPUT SHAFT ASSEMBLY..............................255 DISASSEMBLY OF CARRIER...........................................257 ASSEMBLY OF CARRIER..............................................258 ASSEMBLY OF INPUT SHAFT..........................................259 ASSEMBLY OF NO. 2 HOUSING FR CARRIER ASSEMBLY....................261 ASSEMBLY OF FIRST SPEED CLUTCH ASSEMBLY..........................263 ASSEMBLY OF TRANSMISSION.........................................267 CONNECTION TRANSMISSION AND TORQUE CONVERTER.....................275 DISMOUNTING TRANSMISSION CONTROL VALVE...........................276 MOUNTING TRANSMISSION CONTROL VALVE..............................278 MOUNTING TRANSMISSION CONTROL VALVE..............................284 ASSEMBLY OF TRANSMISSION CONTROL VALVE...........................290 DISMOUNTING TRANSMISSION LUBRICATION VALVE.......................296 MOUNTING TRANSMISSION LUBRICATION VALVE..........................298 DISMOUNTING TRANSMISSION PUMP....................................300 MOUNTING TRANSMISSION PUMP.......................................302 DISMOUNTING BEVEL GEAR SHAFT AND STEERING CLUTCH ASSEMBLY........304 MOUNTING BEVEL GEAR SHAFT AND STEERING CLUTCH ASSEMBLY...........308 DISASSEMBLY OF BEVEL GEAR SHAFT AND STEERING CLUTCH ASSEMBLY.....315 ASSEMBLY OF BEVEL GEAR SHAFT AND STEERING CLUTCH ASSEMBLY........321 ASSEMBLY OF STEERING CLUTCH ASSEMBLY.............................323 ASSEMBLY OF STEERING CLUTCH AND YOKE ASSEMBLY....................325 DISMOUNTING BEVEL PINION ASSEMBLY................................328 MOUNTING BEVEL PINION ASSEMBLY...................................329 DISASSEMBLY OF BEVEL PINION......................................330 ASSEMBLY OF BEVEL PINION ASSEMBLY................................332 DISMOUNTING STEERING CONTROL VALVE ASSEMBLY......................335 MOUNTING STEERING CONTROL VALVE ASSEMBLY.........................336 DISASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY...................337 ASSEMBLY OF STEERING CONTROL VALVE ASSEMBLY......................339 DISMOUNTING FINAL DRIVE FIRST PINION.............................342 MOUNTING FINAL DRIVE FIRST PINION................................344 DISASSEMBLY OF FINAL DRIVE ASSEMBLY..............................347 ASSEMBLY OF FINAL DRIVE ASSEMBLY.................................355 DISMOUNTING STEERING PUMP ASSEMBLY...............................364 MOUNTING STEERING PUMP ASSEMBLY..................................365 DISMOUNTING OPERATOR'S SEAT FRAME ASSEMBLY.......................366 MOUNTING OPERATOR'S SEAT FRAME ASSEMBLY..........................373 24 MAINTENANCE STANDARD..................................................388 MAINTENANCE STANDARD.................................................389 DAMPER ..........................................................390 TORQUE CONVERTER.................................................392 TORQFLOW TRANSMISSION............................................396 TRANSMISSION CONTROL VALVE.......................................400 TRANSMISSION LUBRICATING VALVE...................................404 TRANSMISSION PUMP................................................405 BEVEL GEAR SHAFT, STEERING SYSTEM................................406 STEERING PUMP ...................................................410 FINAL DRIVE......................................................411 30 UNDERCARRIAGE.............................................................414 31 STRUCTURE AND FUNCTION................................................414 STRUCTURE AND FUNCTION...............................................415 TRACK SHOE.......................................................416 TRACK............................................................417 UNDERCARRIAGE....................................................419 33 DISASSEMBLY AND ASSEMBLY..............................................424 DISASSEMBLY AND ASSEMBLY.............................................425 SEPARATION OF SHOE...............................................426 CONNECTION OF SHOE...............................................428 DISMOUNTING CARRIER ROLLER.......................................430 MOUNTING CARRIER ROLLER..........................................431 DISMOUNTING FRONT IDLER..........................................432 MOUNTING FRONT IDLER ASSEMBLY....................................433 DISMOUNTING RECOIL SPRING........................................435 MOUNTING RECOIL SPRING...........................................439 DISMOUNTING OF TRACK FRAME ASSEMBLY..............................442 MOUNTING TRACK FRAME ASSEMBLY....................................444 DISMOUNTING TRACK ROLLER ASSEMBLY................................446 MOUNTING TRACK ROLLER ASSEMBLY...................................448 34 MAINTENANCE STANDARD..................................................450 MAINTENANCE STANDARD.................................................451 TRACK............................................................452 IDLER............................................................454 TRACK ROLLER.....................................................456 CARRIER ROLLER...................................................458 RECOIL SPRING....................................................460 TRACK FRAME......................................................461 60 HYDRAULIC CONTROL SYSTEM..................................................462 61 STRUCTURE AND FUNCTION................................................462 STRUCTURE AND FUNCTION...............................................463 HYDRAULIC SYSTEM.................................................464 BUCKET CONTROL LINKAGE...........................................465 HYDRAULIC SYSTEM.................................................468 HYDRAULIC CIRCUIT................................................469 HYDRAULIC TANK...................................................470 HYDRAULIC PUMP...................................................472 HYDRAULIC FILTER.................................................473 HYDRAULIC CONTROL VALVE..........................................474 MAIN RELIEF VALVE................................................476 SUCTION VALVE....................................................477 SAFETY VALVE.....................................................478 CYLINDER.........................................................480 62 TESTING AND ADJUSTING.................................................482 TESTING AND ADJUSTING................................................483 TABLE OF JUDGEMENT STANDARD VALUE................................484 TESTING AND ADJUSTING TOOL LIST..................................485 MEASURING OF FLOW CAPACITY.......................................486 MEASURING AND ADJUSTING OF OIL PRESSURE..........................488 MEASURING OF CYLINDER DRIFT OF WORK EQUIPMENT....................489 ADJUSTING OF ELECTRICAL POSITIONER...............................489 ADJUSTING KICK-OUT...............................................490 63 DISASSEMBLY AND ASSEMBLY..............................................491 DISASSEMBLY AND ASSEMBLY.............................................492 DISMOUNTING HYDRAULIC PUMP ASSEMBLY..............................493 MOUNTING HYDRAULIC PUMP ASSEMBLY.................................495 DISMOUNTING LIFT CYLINDER ASSEMBLY...............................497 MOUNTING LIFT CYLINDER ASSEMBLY..................................499 DISMOUNTING HYDRAULIC TANK ASSEMBLY..............................505 MOUNTING HYDRAULIC TANK ASSEMBLY.................................509 DISMOUNTING HYDRAULIC CONTROL VALVE ASSEMBLY.....................513 MOUNTING HYDRAULIC CONTROL VALVE ASSEMBLY........................516 DISASSEMBLY OF HYDRAULIC CONTROL VALVE ASSEMBLY..................525 ASSEMBLY OF HYDRAULIC CONTROL VALVE..............................529 DISMOUNTING DUMP CYLINDER........................................533 MOUNTING DUMP CYLINDER...........................................535 64 MAINTENANCE STANDARD..................................................537 MAINTENANCE STANDARD.................................................538 HYDRAULIC PUMP...................................................539 CONTROL VALVE....................................................540 HYDRAULIC CYLINDER...............................................543 70 WORK EQUIPMENT............................................................545 71 STRUCTURE AND FUNCTION................................................545 STRUCTURE AND FUNCTION...............................................546 LIFT ARM AND SIDE FRAME..........................................547 BUCKET...........................................................549 73 DISASSEMBLY AND ASSEMBLY..............................................550 DISASSEMBLY AND ASSEMBLY.............................................551 DISMOUNTING WORK EQUIPMENT ......................................552 MOUNTING WORK EQUIPMENT..........................................556 74 MAINTENANCE STANDARD..................................................560 MAINTENANCE STANDARD.................................................561 LIFT ARM AND SIDE FRAME..........................................562 BUCKET...........................................................564 80 ELECTRICAL SYSTEM.........................................................565 STRUCTURE AND FUNCTION...................................................566 ELECTRICAL CIRCUIT...................................................567
DESCRIPTION:
KOMATSU D57S-1 SHOP MANUAL SEBM0135A05 – PDF DOWNLOAD
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 perforated in a service workshop.
For ease of understanding. the manual is divided into chapters for each main group of components; these chapters are further divided into the following sections.
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 25/12/24
