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Komatsu D75S-5 Dozer Service Manual SEBD01450503 – PDF DOWNLOAD
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Description
Komatsu D75S-5 Dozer Service Manual
FILE DETAILS:
Komatsu D75S-5 Dozer Service Manual
Brands: Komatsu
Manuals Type: Shop Manual
Machine Model: D75S-5
Serial Number: 15001 and up
Book Code: SEBD01450503
Language: English
Pages: 477
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D75S-5 Dozer Service Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
- This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding. the manual is divided into the following chapters; these
chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs. as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating ‘Problems’ to “Causes” are also included In this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu D75S-5 Dozer Service Manual
MAIN MENU................................................................................................................ 0 CONTENTS................................................................................................................. 2 01 GENERAL............................................................................................................... 21 GENERAL ASSEMBLY DRAWING ........................................................................................... 22 SPECIFICATIONS ...................................................................................................... 23 WEIGHT TABLE ........................................................................................................ 26 TABLE OF FUEL, COOLANT AND LUBRICANTS ............................................................................... 28 10 ENGINE................................................................................................................ 29 12 ENGINE TESTING AND ADJUSTING...................................................................................... 29 STANDARDS FOR TESTING AND ADJUSTING ............................................................................. 30 TOOLS FOR TESTING AND ADJUSTING ................................................................................. 32 CHECKING AND ADJUSTING FUEL INJECTION TIMING .................................................................... 34 MEASURING BLOW-BY................................................................................................ 36 MEASURING AIR SUPPLY PRESSURE .................................................................................. 37 MEASURING EXHAUST COLOR ......................................................................................... 38 MEASURING EXHAUST TEMPERATURE ................................................................................... 39 MEASURING ENGINE OIL PRESSURE ................................................................................... 40 MEASURING ENGINE SPEED .......................................................................................... 40 ADJUSTING VALVE CLEARANCE ....................................................................................... 41 MEASURING COMPRESSION PRESSURE .................................................................................. 43 CHECKING AND ADJUSTING FAN BELT TENSION ......................................................................... 45 MEASURING TORQUE CONVERTER STALL SPEED ......................................................................... 46 BLEEDING AIR FROM FUEL FILTER ................................................................................... 47 BLEEDING AIR FROM HYDRAULIC CYLINDER .......................................................................... 47 TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)........................................................................ 48 METHOD OF USING TROUBLESHOOTING CHARTS ..................................................................... 49 S-1 Starting performance is poor (starting always takes time)................................................ 53 S-2 Engine does not start.................................................................................... 54 (1) Engine does not turn................................................................................. 54 (2) Engine turns but no exhaust smoke comes out (fuel is not being injected)............................. 55 (3) Exhaust smoke comes out but engine does not start (Fuel is being injected)........................... 56 S-3 Engine does not pick up smoothly (follow-up is poor)..................................................... 57 S-4 Engine stops during operations........................................................................... 58 S-5 Engine does not rotate smoothly (hunting)................................................................ 59 S-6 Engine lacks output (no power)........................................................................... 60 S-7 Exhaust smoke is black (incomplete combustion)........................................................... 61 S-8 Oil consumption is excessive (or exhaust smoke is blue).................................................. 62 S-9 Oil becomes contaminated quickly......................................................................... 63 S-10 Fuel consumption is excessive........................................................................... 64 S-11 Oil is in cooling water, or water spurts back, or water level goes down................................. 65 S-12 Oil pressure caution lamp lights up (drop in oil pressure).............................................. 66 S-13 Oil level rises (water, fuel in oil).................................................................... 67 S-14 Water temperature becomes too high (overheating)........................................................ 68 S-15 Abnormal noise is made.................................................................................. 69 S-16 Vibration is excessive.................................................................................. 70 13 DISASSEMBLY AND ASSEMBLY.......................................................................................... 71 STARTING MOTOR................................................................................................... 72 DISMOUNTING.................................................................................................. 72 MOUNTING..................................................................................................... 72 ALTERNATOR....................................................................................................... 73 DISMOUNTING.................................................................................................. 73 MOUNTING .................................................................................................... 73 WATER PUMP....................................................................................................... 74 DISMOUNTING.................................................................................................. 74 MOUNTING .................................................................................................... 74 THERMOSTAT ...................................................................................................... 76 DISMOUNTING.................................................................................................. 76 MOUNTING..................................................................................................... 76 TORQUE CONVERTER COOLER.......................................................................................... 77 DISMOUNTING.................................................................................................. 77 MOUNTING..................................................................................................... 78 FUEL INJECTION PUMP.............................................................................................. 79 DISMOUNTING.................................................................................................. 79 MOUNTING..................................................................................................... 79 ENGINE OIL COOLER................................................................................................ 81 DISMOUNTING.................................................................................................. 81 MOUNTING..................................................................................................... 81 TURBOCHARGER..................................................................................................... 82 DISMOUNTING.................................................................................................. 82 MOUNTING..................................................................................................... 82 NOZZLE HOLDER.................................................................................................... 83 DISMOUNTING.................................................................................................. 83 MOUNTING .................................................................................................... 84 CYLINDER HEAD.................................................................................................... 85 DISMOUNTING.................................................................................................. 85 MOUNTING..................................................................................................... 91 INSTALLATION.................................................................................................103 ENGINE FRONT SEAL................................................................................................105 REMOVAL......................................................................................................105 INSTALLATION.................................................................................................105 ENGINE REAR SEAL.................................................................................................106 REMOVAL......................................................................................................106 INSTALLATION.................................................................................................107 ENGINE...........................................................................................................110 DISMOUNTING..................................................................................................110 MOUNTING.....................................................................................................120 RADIATOR GUARD...................................................................................................136 DISMOUNTING..................................................................................................136 MOUNTING.....................................................................................................139 FUEL TANK........................................................................................................142 REMOVAL......................................................................................................142 INSTALLATION.................................................................................................143 20 POWER TRAIN...........................................................................................................144 21 STRUCTURE AND FUNCTION............................................................................................144 GENERAL .........................................................................................................145 TORQUE CONVERTER.................................................................................................147 PTO (POWER TAKE-OFF).............................................................................................151 TORQFLOW TRANSMISSION............................................................................................152 TORQFLOW TRANSMISSION CONTROL....................................................................................164 STEERING AND TORQFLOW HYDRAULIC SYSTEM (PIPING)..................................................................165 SCHEMATIC OF TORQFLOW HYDRAULIC SYSTEM...........................................................................167 TORQFLOW HYDRAULIC CIRCUIT DIAGRAM...............................................................................168 SCHEMATIC OF TORQFLOW HYDRAULIC SYSTEM...........................................................................169 TORQFLOW HYDRAULIC CIRCUIT DIAGRAM...............................................................................170 TRANSMISSION CONTROL VALVE.......................................................................................171 TRANSMISSION LUBRICATING SYSTEM..................................................................................177 TRANSMISSION LUBRICATING RELIEF VALVE............................................................................178 TORQFLOW AND STEERING PUMP.......................................................................................179 TORQFLOW AND STEERING OIL FILTER.................................................................................180 SCHEMATIC OF STEERING HYDRAULIC SYSTEM...........................................................................181 STEERING HYDRAULIC CIRCUIT DIAGRAM...............................................................................182 BEVEL GEAR AND STEERING CLUTCH...................................................................................183 STEERING BRAKE ..................................................................................................187 STEERING CONTROL VALVE...........................................................................................191 STEERING MAIN RELIEF VALVE.......................................................................................194 STEERING CONTROL ................................................................................................195 FINAL DRIVE......................................................................................................196 22 TESTING AND ADJUSTING.............................................................................................197 STANDARDS FOR TESTING AND ADJUSTING..............................................................................198 TESTING AND ADJUSTING TOOL LIST..................................................................................200 TROUBLESHOOTING..................................................................................................206 PREPARATION FOR TROUBLESHOOTING .............................................................................207 HOW TO USE DIAGNOSTIC TABLES.................................................................................209 PREVENTING RECURRENCE OF THE SAME TROUBLE....................................................................211 TROUBLESHOOTING..............................................................................................212 1. Torque converter temperature too high.................................................................212 2. Machine does not move.................................................................................213 3. Machine lacks power or speed..........................................................................215 4. Machine moves when engine is started..................................................................217 5. Excessive time lag when starting machine or shifting gear.............................................218 6. Excessive shock when starting machine or shifting gear................................................219 7. Transmission shift lever comes out....................................................................219 8. Transmission shift lever is heavy.....................................................................219 9. Oil level in transmission case or steering case changes...............................................219 10. Steering clutch does not disengage...................................................................220 11. Steering clutch slips................................................................................221 12. Steering brake does not work.........................................................................222 23 DISASSEMBLY AND ASSEMBLY..........................................................................................223 TORQUE CONVERTER RELIEF VALVE....................................................................................224 DISMOUNTING..................................................................................................224 MOUNTING.....................................................................................................224 TORQUE CONVERTER.................................................................................................225 DISMOUNTING..................................................................................................225 MOUNTING.....................................................................................................229 TORQUE CONVERTER AND PTO.........................................................................................233 DISASSEMBLY..................................................................................................233 ASSEMBLY.....................................................................................................239 TORQFLOW TRANSMISSION............................................................................................247 DISMOUNTING..................................................................................................247 MOUNTING.....................................................................................................252 DISASSEMBLY (1/2)............................................................................................257 DISASSEMBLY (2/2)............................................................................................265 ASSEMBLY (1/2)...............................................................................................267 ASSEMBLY (2/2)...............................................................................................271 TRANSMISSION CONTROL VALVE.......................................................................................280 DISMOUNTING..................................................................................................280 MOUNTING.....................................................................................................283 DISASSEMBLY (1/2)............................................................................................286 ASSEMBLY (1/2)...............................................................................................286 DISASSEMBLY (2/2)............................................................................................287 ASSEMBLY (2/2)...............................................................................................287 BEVEL PINION.....................................................................................................288 DISMOUNTING..................................................................................................288 MOUNTING.....................................................................................................288 DISASSEMBLY..................................................................................................289 ASSEMBLY.....................................................................................................289 TANDEM PUMP......................................................................................................291 DISMOUNTING..................................................................................................291 MOUNTING.....................................................................................................291 STEERING CLUTCH..................................................................................................292 DISMOUNTING..................................................................................................292 MOUNTING.....................................................................................................295 DISASSEMBLY..................................................................................................299 ASSEMBLY.....................................................................................................300 BEVEL GEAR.......................................................................................................301 DISMOUNTING..................................................................................................301 MOUNTING.....................................................................................................304 STEERING CONTROL VALVE...........................................................................................310 DISMOUNTING..................................................................................................310 MOUNTING.....................................................................................................310 DISASSEMBLY..................................................................................................311 ASSEMBLY.....................................................................................................311 STEERING MAIN RELIEF VALVE.......................................................................................313 DISASSEMBLY..................................................................................................313 ASSEMBLY.....................................................................................................313 FINAL DRIVE 1ST PINION...........................................................................................315 DISMOUNTING..................................................................................................315 MOUNTING.....................................................................................................316 FINAL DRIVE......................................................................................................317 DISASSEMBLY..................................................................................................317 ASSEMBLY.....................................................................................................320 24 MAINTENANCE STANDARD..............................................................................................325 TORQUE CONVERTER ................................................................................................326 TORQFLOW TRANSMISSION ...........................................................................................329 TRANSMISSION CONTROL VALVE.......................................................................................333 TRANSMISSION LUBRICATION VALVE ..................................................................................335 TRANSMISSION, STEERING PUMP .....................................................................................336 BEVEL GEAR AND STEERING CLUTCH ..................................................................................337 STEERING MAIN RELIEF VALVE ......................................................................................341 STEERING CONTROL VALVE .........................................................................................342 STEERING BRAKE...................................................................................................344 FINAL DRIVE .....................................................................................................346 30 UNDERCARRIAGE.........................................................................................................350 31 STRUCTURE AND FUNCTION............................................................................................350 TRACK GROUP......................................................................................................351 RECOIL SPRING....................................................................................................352 IDLER............................................................................................................353 TRACK ROLLER AND CARRIER ROLLER..................................................................................354 TRACK SHOE.......................................................................................................355 SUSPENSION ......................................................................................................359 33 DISASSEMBLY AND ASSEMBLY..........................................................................................360 CARRIER ROLLER...................................................................................................361 DISMOUNTING..................................................................................................361 MOUNTING.....................................................................................................361 TRACK ROLLER.....................................................................................................362 DISMOUNTING..................................................................................................362 MOUNTING.....................................................................................................362 FRONT IDLER......................................................................................................363 DISMOUNTING..................................................................................................363 MOUNTING.....................................................................................................363 TRACK SHOE.......................................................................................................364 CHECKING BEFORE REMOVAL......................................................................................364 REMOVAL (NORMAL) ............................................................................................364 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME) ......................................................365 INSTALLATION ................................................................................................366 RECOIL SPRING....................................................................................................367 DISMOUNTING..................................................................................................367 MOUNTING.....................................................................................................370 DISASSEMBLY..................................................................................................373 ASSEMBLY ....................................................................................................374 TRACK FRAME......................................................................................................375 DISMOUNTING..................................................................................................375 MOUNTING.....................................................................................................377 34 MAINTENANCE STANDARD..............................................................................................379 TRACK GROUP......................................................................................................380 RECOIL SPRING ...................................................................................................381 IDLER............................................................................................................382 TRACK ROLLER ....................................................................................................384 CARRIER ROLLER ..................................................................................................386 TRACK............................................................................................................387 SUSPENSION.......................................................................................................395 60 HYDRAULIC SYSTEM......................................................................................................396 61 STRUCTURE AND FUNCTION............................................................................................396 HYDRAULIC SYSTEM (PIPING) ......................................................................................397 SCHEMATIC OF HYDRAULIC SYSTEM....................................................................................398 HYDRAULIC CIRCUIT DIAGRAM........................................................................................399 HYDRAULIC TANK ..................................................................................................400 HYDRAULIC FILTER.................................................................................................401 HYDRAULIC PUMP ..................................................................................................402 HYDRAULIC CONTROL VALVE .......................................................................................403 MAIN RELIEF VALVE................................................................................................404 SUCTION VALVE....................................................................................................405 SAFETY VALVE ....................................................................................................406 HYDRAULIC CYLINDER...............................................................................................408 62 TESTING AND ADJUSTING.............................................................................................409 STANDARDS FOR TESTING AND ADJUSTING..............................................................................410 TESTING AND ADJUSTING TOOL LIST..................................................................................411 POINTS FOR MEASURING HYDRAULIC PRESSURE .......................................................................412 ADJUSTING HYDRAULIC PRESSURE OF RELIEF VALVE.....................................................................412 PERFORMANCE OF HYDRAULIC PUMP ...................................................................................413 TROUBLESHOOTING..................................................................................................414 1. LIFT ARM LACKS LIFTING POWER OR SPEED.....................................................................415 2. LIFT ARM DOES NOT MOVE....................................................................................416 3. HYDRAULIC DRIFT OF LIFT ARM IS EXCESSIVE..................................................................417 4. LACK OF TILT-BACK POWER OR SPEED (DUMP AND TILT BACK).....................................................418 5. DUMP CYLINDER DOES NOT MOVE...............................................................................419 6. HYDRAULIC DRIFT OF BUCKET (DUMP) IS EXCESSIVE.............................................................420 7. CONTROL LEVER IS HEAVY....................................................................................421 8. DURING LEVELING OPERATIONS (CONTROL LEVER AT HOLD), BUCKET FOLLOWS LEVEL OF GROUND AND LIFT ARM WAVERS....422 9. LIFT ARM DROPS............................................................................................422 1) Lift arm temporarily drops when lift control lever is moved from HOLD or RAISE........................422 2) Lift arm slowly moves down when lift control lever is moved to RAISE with engine stopped..............422 10. BUCKET WAVERS WHEN TRAVELING IN REVERSE DURING LEVELING OPERATIONS (CONTROL LEVER AT HOLD)...............422 11. BUCKET TIPS FORWARD......................................................................................422 1) Bucket temporarily tips forward when dump control lever is moved from HOLD to TILT....................422 2) Bucket slowly tips forward when dump control lever is moved to TILT with engine stopped...............422 12. LIFT ARM DOES NOT MOVE UP WHEN BUCKET IS AT MAXIMUM DUMP.................................................422 63 DISASSEMBLY AND ASSEMBLY..........................................................................................423 HYDRAULIC PUMP...................................................................................................424 DISMOUNTING..................................................................................................424 MOUNTING ....................................................................................................425 MAIN CONTROL VALVE...............................................................................................426 DISMOUNTING..................................................................................................426 MOUNTING ....................................................................................................427 HYDRAULIC CONTROL VALVE .........................................................................................428 DISASSEMBLY (1/2)............................................................................................428 ASSEMBLY (1/2)..............................................................................................428 DISASSEMBLY (2/2)...........................................................................................430 ASSEMBLY (2/2)...............................................................................................430 DUMP CYLINDER....................................................................................................432 DISMOUNTING..................................................................................................432 MOUNTING.....................................................................................................432 LIFT CYLINDER ...................................................................................................433 DISMOUNTING..................................................................................................433 MOUNTING ....................................................................................................433 HYDRAULIC CYLINDER ..............................................................................................434 DISASSEMBLY..................................................................................................434 ASSEMBLY ....................................................................................................436 64 MAINTENANCE STANDARD..............................................................................................439 HYDRAULIC FILTER.................................................................................................440 HYDRAULIC PUMP...................................................................................................441 HYDRAULIC CONTROL VALVE .........................................................................................442 MAIN RELIEF VALVE ...............................................................................................443 SUCTION VALVE ...................................................................................................444 SAFETY VALVE ....................................................................................................445 HYDRAULIC CYLINDER...............................................................................................446 70 WORK EQUIPMENT........................................................................................................448 71 STRUCTURE AND FUNCTION............................................................................................448 POSITIONER CONTROL...............................................................................................449 KICK OUT CONTROL ...............................................................................................450 LIFT ARM AND SIDE FRAME ........................................................................................451 BUCKET ..........................................................................................................452 73 DISASSEMBLY AND ASSEMBLY..........................................................................................453 WORK EQUIPMENT ..................................................................................................454 DISMOUNTING..................................................................................................454 MOUNTING.....................................................................................................456 FUEL TANK .......................................................................................................458 DISMOUNTING..................................................................................................458 MOUNTING ....................................................................................................458 OPERATORS COMPARTMENT FRAME AND COVER ASSEMBLY ..................................................................459 DISMOUNTING..................................................................................................459 MOUNTING.....................................................................................................462 74 MAINTENANCE STANDARD..............................................................................................465 LIFT ARM AND SIDE FRAME .........................................................................................466 BUCKET ..........................................................................................................468 80 ELECTRICAL SYSTEM.....................................................................................................469 81 STRUCTURE AND FUNCTION............................................................................................469 ELECTRICAL WIRING................................................................................................470 ELECTRICAL CIRCUIT DIAGRAM.......................................................................................471 82 TESTING AND ADJUSTING.............................................................................................472 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)....................................................................473 E-1 Engine does not start....................................................................................474 E-2 Preheating does not work.................................................................................476
KOMATSU D75S-5 DOZER SERVICE MANUAL SEBD01450503 – PDF DOWNLOAD:
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