Komatsu d575 a 2 dozer bulldozer service repair manual (sn 10001 and up)

SEBM000105
KOMA’SU
D57SA=z
MACHINE MODEL SERIAL NUMBER
D575A-2 10001 and up
This shop manual may contain attachments and optional equipment that are not available in
your area. Please consult your local Komatsu distributor for those items you may require.
Materials and specifications are subject to change without notice.
D575A-2 mounts the SA12V170-1 engine.
For details of the engine, see the 12V170-1 Series Engine Shop Manual.
0 1995 K-lb!
All Rights Reserved
09-95(02)00401
00-l
0

CONTENTS
No. of page
01 GENERAL ......................................................... 01-1
10 STRUCTURE AND FUNCTION ........................... IO-I
20 TESTING AND ADJUSTING .............................. 20-1
30 DISASSEMBLY AND ASSEMBLY ...................... 30-1
40 MAINTENANCE STANDARD ............................ 40-1
s
H

SAFETY SAFETY NOTICE
SAFETY
SAFETY NOTICE
IMPORTANT SAFETY NOTICE
Proper service and repair is extremely important for safe machine operation. The
service and repair techniques recommended by Komatsu and described in this manual
are both effective and safe. Some of these techniques require the use of tools specially
designed by Komatsu for the specific purpose.
To prevent injury to workers, the symbol A. IS used to mark safety precautions in this
manual. The cautions accompanying these symbols should always be followed care-
fully. If any dangerous situation arises or may possibly arise, first consider safety, and
take the necessary actions to deal with the situation.
GENERAL PRECAUTIONS
Mistakes in operation are extremely dangerous.
Read the Operation and Maintenance Manual
carefully BEFORE operating the machine.
1.
2.
3.
4.
5.
Before carrying out any greasing or repairs,
read all the precautions given on the decals
which are fixed to the machine.
When carrying out any operation, always
wear safety shoes and helmet. Do not wear
loose work clothes, or clothes with buttons
missing.
. Always wear safety glasses when hitting
parts with a hammer.
. Always wear safety glasses when grind-
ing parts with a grinder, etc.
If welding repairs are needed, always have a
trained, experienced welder carry out the
work. When carrying out welding work, al-
ways wear welding gloves, apron, glasses,
cap and other clothes suited for welding
work.
When carrying out any operation with two
or more workers, always agree on the oper-
ating procedure before starting. Always in-
form your fellow workers before starting any
step of the operation. Before starting work,
hang UNDER REPAIR signs on the controls
in the operator’s compartment.
Keep all tools in good condition and learn
the correct way to use them.
6. Decide a place in the repair workshop to
keep tools and removed parts. Always keep
the tools and parts in their correct places.
Always keep the work area clean and make
sure that there is no dirt or oil on the floor.
Smoke only in the areas provided for smok-
ing. Never smoke while working.
PREPARATIONS FOR WORK
7.
8.
9.
10.
Before adding oil or making any repairs,
park the machine on hard, level ground, and
block the wheels or tracks to prevent the
machine from moving.
Before starting work, lower blade, ripper,
bucket or any other work equipment to the
ground. If this is not possible, insert the
safety pin or use blocks to prevent the work
equipment from falling. In addition, be sure
to lock all the control levers and hang warn-
ing signs on them.
When disassembling or assembling, support
the machine with blocks, jacks or stands
before starting work.
Remove all mud and oil from the steps or
other places used to get on and off the ma-
chine. Always use the handrails, ladders or
steps when getting on or off the machine.
Never jump on or off the machine. If it is
impossible to use the handrails, ladders or
steps, use a stand to provide safe footing.
00-3

SAFETY SAFETY NOTICE
PRECAUTIONS DURING WORK
11. When removing the oil filler cap, drain plug
or hydraulic pressure measuring plugs,
loosen them slowly to prevent the oil from
spurting out.
Before disconnecting or removing compo-
nents of the oil, water or air circuits, first
remove the pressure completely from the
circuit.
12. The water and oil in the circuits are hot
when the engine is stopped, so be careful
not to get burned.
Wait for the oil and water to cool before
carrying out any work on the oil or water
circuits.
13. Before starting work, remove the leads from
the battery. Always remove the lead from
the negative (-) terminal first.
14. When raising heavy components, use a hoist
or crane.
Check that the wire rope, chains and hooks
are free from damage.
Always use lifting equipment which has
ample capacity.
Install the lifting equipment at the correct
places. Use a hoist or crane and operate
slowly to prevent the component from hit-
ting any other part. Do not work with any
part still raised by the hoist or crane.
15. When removing covers which are under in-
ternal pressure or under pressure from a
spring, always leave two bolts in position
on opposite sides. Slowly release the pres-
sure, then slowly loosen the bolts to remove.
16. When removing components, be careful not
to break or damage the wiring. Damaged
wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil
from spilling out. If any fuel or oil drips onto
the floor, wipe it up immediately. Fuel or oil
on the floor can cause you to slip, or can
even start fires.
18. As a general rule, do not use gasoline to
wash parts. In particular, use only the mini-
mum of gasoline when washing electrical
parts.
00-4
19. Be sure to assemble all parts again in their
original places.
Replace any damaged parts with new parts.
. When installing hoses and wires, be sure
that they will not be damaged by contact
with other parts when the machine is be-
ing operated.
20. When installing high pressure hoses, make
sure that they are not twisted. Damaged
tubes are dangerous, so be extremely care-
ful when installing tubes for high pressure
circuits. Also, check that connecting parts
are correctly installed.
21. When assembling or installing parts, always
use the specified tightening torques. When
installing protective parts such as guards,
or parts which vibrate violently or rotate at
high speed, be particularly careful to check
that they are installed correctly.
22. When aligning two holes, never insert your
fingers or hand. Be careful not to get your
fingers caught in a hole.
23. When measuring hydraulic pressure, check
that the measuring tool is correctly assem-
bled before taking any measurements.
24. Take care when removing or installing the
tracks of track-type machines.
When removing the track, the track sepa-
rates suddenly, so never let anyone stand at
either end of the track.

REMOVAL OF POWER TRAIN OIL COOLER ASSEMBLY
1.
2.
3.
4.
5.
6.
Remove engine hood.
For details, see REMOVAL OF ENGINE ASSEMBLY.
Remove radiator top cover.
Open underguard.
For details, see REMOVAL OF FAN MOTOR
ASSEMBLY.
Disconnect cooler inlet hose (1).
l For R.H. cooler
* 50 - 60 liters of oil will flow out, so prepare
a container to catch it.
Disconnect cooler outlet hose (2).
l For L.H. cooler
Ir 50 - 60 liters of oil will flow out, so prepare
a container to catch it.
Disconnect hose (3).
* Disconnect only from the cooler that is to be
removed.
7. Remove cushion (4).
* Remove only from the cooler that is to be
removed.
30-16
8

8. Remove hose (5).
9. Remove pin (6).
It Remove only from the cooler that is to be
removed.
10. Remove bracket (7).
* Remove only from the cooler that is to be
removed.
* On the left side, remove the clamp of wiring
harness (8), and move it the side.
11. Lift off power train cooler assembly (9).
Power train cooler assembly: 150 kg
Ii c’9M02310

INSTALLATION OF POWER TRAIN OIL COOLER ASSEMBLY
. Carry out installation in the reverseorderto removal.
_
. Refilling with oil
+ Add oil to replace the oil that leaked out when
the cooler was removed.
Add oil to the specified level, and run the engine
to circulate the oil through the system. Then
check the oil level again.
0
C’

REMOVAL OF HYDRAULIC COOLER ASSEMBLY
1. Remove fan motor assembly.
SUPPORT ASSEMBLY.
2. Remove hose (1).
3. Remove block (2).
4. Remove cooler assemblies (3) and (4).
Hydraulic cooler assembly (each): 45 kg
INSTALLATION OF HYDRAULC
COOLER ASSEMBLY
. Carry out installation in the reverse orderto removal.
. Refilling with oil
+ Add oil to replace the oil that leaked out when
the cooler was removed.
Add oil to the specified level, and run the engine
to circulate the oil through the system. Then
check the oil level again.
r
-19M02311
jiL’
====% 9M02312

REMOVAL OF FUEL INJECTION PUMP ASSEMBLY (Left and right)
1.
2.
3.
4.
.
Link
1) Cut seal and remove center bolt (6). m
2) Loosen locknut (7), then remove stud (8).
3) Remove cover (9).
I F19M02902
4) Remove link (10).
Remove engine hood.
Remove air cleaner and muffler assembly.
For details, see REMOVAL OF CYLINDER HEAD
ASSEMBLY.
Close fuel supply valve.
Injection pump for left bank
1) Remove injection pipe (1). m
2) Disconnect lubrication hose (2) and air hose (3).
F19M02903

3) Disconnect fuel hose (4).
4) Remove injection pump assembly (5). m
* Remove the mounting bolts, move it towards
the rear, then lift it out.
pump assembly (with governor):
47 kg
. Injection pump for right bank
1) Remove injection pipe (1). m
2) Disconnect hose (6), (7) and tube (8).
3) Disconnect lubrication tube (9).
F19M02314

4) Disconnect fuel hose (10).
5) Remove injection pump assembly (11). m
* Remove the mounting bolts, move it towards
the rear, then lift it out.
el
kg Injection pump assembly
(without governor): 30 kg
F19M02317

INSTALLATION OF FUEL INJECTION PUMP ASSEMBLY
(Left and right)
. Carry out installation in thereverseorderto removal.
m
w Sleeve nut: 2.25 F 0.25 kgm
* Align the spline of the coupling and install, then
align the line of the body, and tighten the
mounting bolts.
* Adjust the fuel injection timing, and adjust the
injection amount for the left and right banks.
For details, see TESTING AND ADJUSTING.
l Install ling as follows.
1) Insert pins at tips of link (10) into both rack
2)
3)
4)
Pull link (10) towards injection pump, pass
stud (8) through nut inside link, then tighten
approx. 4 turns.
Pass stud (8) through stud hole in housing
(11) and turn until it contacts the end. (approx.
7 turns = 14 mm)
After it contacts the end, turn stud (8) back
approx. 2 turns.
* The stud moves 4 mm and the center of
5)
6)
the link fulcrum moves 2 mm forwards.
Tighten locknut (7) temporarily.
Fit O-ring on top of link, then fit gasket and
install cover (9).
7) Fit washer, then tighten center bolt (6).
joints.
w Center bolt : 5.5 * 2 kgm
* Adjust the difference in exhaust temper-
ature between the left and right. For
details, see TESTING AND ADJUSTING.
I F19M02904
F19M02905
9 6
I’ ‘I
F19M02906

REMOVAL OF WATER PUMP ASSEMBLY
1. Drain cooling water.
2. Remove engine side cover (right).
3. Open main frame right side cover.
4. Remove exhaust pipe cover (1).
5. Remove tube (2).
P19M02012
6. Remove tube (3).
+ Remove bolts (4), and pull out.
7.
8.
9.
Disconnect hose (5).
Remove tube (6).
Remove water pump assembly (7).
* Raise the water pump assembly from above, then
remove the mounting bolts and lower it.
Water pump assembly: 35 kg
INSTALLATION OF WATER PUMP
ASSEMBLY
F19M0231!
. Refilling with water
Add water to the specified level, and run the engine
to circulate the water through the system. Then
check the water level again.
30&23

REMOVAL OF TURBOCHARGER ASSEMBLY (Left)
+ Drain about l/3 of the cooling water.
2. Remove engine hood.
3. Remove intake connectors (1) and (2).
4. Remove air intake connector (3).
5. Remove cover (4).
6. Remove tubes (5) and (6).
7. Disconnect tubes (7) and (8).
8. Remove turbocharger assembly (left) (9). m
Turbocharger assembly: 35 kg
INSTALLATION OF TURBOCHARGER
ASSEMBLY (Left)
m
w Mounting bolt: 8.5 k 0.5 kgm
0
P19M02015

REMOVAL OF TURBOCHARGER ASSEMBLY (Right)
+ Drain about l/3 of the cooling water.
3. Remove intake connector (1).
4. Remove air intake connector (2).
5. Remove cover (3).
6. Remove tubes (4) and (5).
7. Disconnect tubes (6) and (7).
8. Remove turbocharger assembly (right) (8). m
6 kg Turbocharger assembly: 35 kg
INSTALLATION OF TURBOCHARGER
ASSEMBLY (Right)
. Carry out installation in the reverse order to removal.
w Mounting bolt: 8.5 I!Z0.5 kgm

REMOVAL OF AFTER-COOLER CORE ASSEMBLY
1. Remove air cleaner assembly and muffler assembly
For details, see REMOVAL OF CYLINDER ASSEM.
BLY.
2. Remove connector (l), tube (2), and connectors (3).
* Remove 2 connectors (3) (top and bottom).
3. Remove tube (4).
4. Remove connector (5), tube (6). and connector (7).
* Remove 2 connectors (7) (top and bottom).
5. Remove tube (8).
6. Remove cover assemblies (9) and (10).
7. Remove cores (11) and (12) from cover assemblies
(9) and (10).
INSTALLATION OF AFTER-COOLER
CORE ASSEMBLY
F19M02321

REMOVAL OF NOZZLE HOLDER ASSEMBLY
1. Remove fuel injection pipe (1) on side to be removed.
m
2. Remove spill hose (2).
3. Remove joint (3).
4. Remove head cover (4). 1#21
5. Remove nozzle holder assembly (5). m
INSTALLATION OF NOZZLE
HOLDER ASSEMBLY
D Sleeve nut: 2.25 AI 0.25 kgm
Ir Tighten the head cover mounting bolts in the
order shown in the diagram below.
198F1302
m Mounting bolt: 3.25 f 0.25 kgm
m Nozzle holder mounting bolt:
2.75 + 0.25 kgm
30-27
I@

REMOVAL OF CYLINDER HEAD ASSEMBLY
For details, see REMOVAL OF ENGINE ASSEMBLY
3. Remove engine side cover.
4. Remove air cleaner and muffler assembly.
1) Disconnect tube (1) and hose (2).
2) Disconnect rods (3) and (4).
3) Remove pipe (5).
4) Remove plate (6).
5) Remove air cleaner and muffler assembly (7).
+ Raise the air cleaner lightly, pull out from the
intake connector, then remove.
el
kg Air cleaner, muffler assembly: 610 kg
0
P19M02032
30628

5. Remove left and right exhaust manifold covers (8).
I (Left)
F19M02324
6. Remove exhaust manifold (9). m
(Left)
9
F19M02325
(Right)
Fl SM02326
30629

7. Remove fuel injection tube (10). m
8. Remove spill hose (11).
9. Remove joint (12). then remove head cover (13).
m
10. Remove nozzle holder (14). m’
11. Remove rocker arm assembly (15). m (nsJ
* Loosen locknut (,16), then loosen adjustment
screw (17) 2 - 3 turns.
12. Disconnect tube (18)
_1 .r
F19M02327

13. Remove rocker arm housing (19). m
+ Pull out pin (20), then put a rod in contact with
portion @, and hit with a hammer in the direction
shown by the arrow to move pipe (21) aside.
14. Remove push rod (22). I#81
15. Remove crosshead (23). m
16. Remove cylinder head assembly (24). m
* Remove the head bolt, then remove the cylinder
head assembly using lifting tool @.
Cylinder head assembly: 40 kg

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INSTALLATION CYLINDER HEAD ASSEMBLY
Fig 1 (Lef? side)
m
+ Install the exhaust manifold, and tighten in the ) I
following order and to the following torque.
i) Install in the order A - B - C shown in Figs.
1 and 2.
ii) Tighten in the order shown in Figs. 3 and 4.
Fig. 3 (left side)
F19M02329
F6,66, ,6 Fig 2 (Right side)
Fig. 4 (right side)
B A C
F19M02330
w Mounting bolts: 1st step 5 z!z1 kgm
2nd step 8.5 + 0.5 kgm
m Sleeve nut: 2.25 I!Z0.25 kgm
* Tighten the head cover mounting bolts in the
order shown in Fig. 5.
w Mounting bolt: 3.25 t 0.25 kgm
w Nozzle holder mounting bolt: 2.75 + 0.25 kgm
Fig 5
5
/
1
0
2
cl
-3 4
198F1302

+ Check that the ball of the adjustment screw is
fitted securely in the socket of the push rod.
QZ Rocker arm mounting bolt: 10 + 0.5 kgm
* Adjust the valve clearance.
For details, see TESTING AND ADJUSTING,
Adjusting valve clearance.
w Rocker arm, screw, locknut: 6.9 ?z 1.O kgm
w Rocker arm housing mounting bolt:
10 + 0.5 kgm
+ Check that the push rod is fitted securely in the
cam follower.
+ Adjust the crosshead as follows.
4
ii)
iii)
iv)
Loosen the locknut, and turn back the
adjustment screw.
Press down lightly on the top surface of the
crosshead, and screw in the adjusment
screw.
After the adjustment screw contacts the valve
stem, tighten it a further 20°.
Tighten the locknut to hold the screw in
position.
w Locknut: 5.6 f 0.4 kgm
* Tighten the cylinder head bolts in the order shown
in Fig. 6.
& Bolt thread, seat surface:
Anti-friction compound (LM-P)
D Cylinder head bolt:
Unit: kgm
Fig 6
I 198F1305

REMOVAL OF RADIATOR ASSEMBLY
3. Remove radiator top cover.
4. Open underground.
ASSEMBLY.
5. Disconnect radiator outlet tube (1).
6. Disconnect wiring (2).
* Remove the connector and clamp, and disconnect
from the radiator.
7. Disconnect hoses (3). (4). and (5).
8. Remove left and right cushions (6).
9. Remove left and right pins (7).
10. Remove left and right brackets (8)

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