Positioning:
Essential documentation for owners, operators, and maintenance personnel of the Komatsu D20P-5, D20PL-5, and D20A-5 series crawler dozers. Targets the construction, agricultural, and landscaping sectors requiring reliable heavy equipment.
Competition:
This manual competes with other OEM or third-party service manuals for similar-sized crawler dozers from manufacturers like Caterpillar, John Deere, and Case. Its value lies in its specific coverage of the Komatsu D20 series.
Features:
Comprehensive coverage of all major systems, detailed troubleshooting guides, extensive diagrams and illustrations, precise technical specifications, and step-by-step repair procedures.
Major Systems:
Engine, Powertrain (Transmission, Final Drives, Undercarriage), Hydraulic System, Steering System, Braking System, Electrical System, Operator's Cab, Attachments, Chassis and Frame
Repair And Maintenance:
Routine Maintenance, Troubleshooting, Component Removal and Installation, Overhaul Procedures, Adjustments, Specifications, Diagrams, Electrical Schematics, Hydraulic Schematics
Assembly Disassembly:
Detailed step-by-step instructions for removing, disassembling, inspecting, repairing, reassembling, and installing all major components and sub-assemblies.
Depth:
Comprehensive: Covers everything from basic checks and fluid changes to complete engine and transmission rebuilds, including detailed diagnostic procedures and torque specifications.
Troubleshooting Methods:
Systematic approach including symptom identification, probable causes, inspection procedures, and corrective actions for engine, hydraulic, transmission, and electrical faults.
Specific Areas:
Engine Tuning and Overhaul, Hydraulic Pump and Valve Repair, HST Unit Service, Final Drive and Planetary Gear Service, Undercarriage Inspection and Repair, Electrical System Diagnostics (including starter, alternator, wiring harness), Operator's Cabin Servicing (seals, controls, HVAC if applicable).
Format Details:
Searchable PDF, High Resolution Scans, Printable Pages
Quality:
Excellent clarity for diagrams, text, and schematics, optimized for professional use.
Binding:
N/A (Digital PDF Download)
Paper:
N/A (Digital PDF Download)
Engine Model:
Komatsu 4D95L (typically, specific variant may apply)
Horsepower:
Approx. 54 HP (Net) / 58 HP (Gross) - Varies slightly by specific configuration.
Displacement:
3.28 Liters (200.2 cu. in.)
Peak Torque:
Approx. 172 Nm (127 lb-ft) at 2000 RPM (Consult manual for exact figure).
Injection Type:
Direct Injection (typically)
Coolant Type:
Ethylene Glycol based coolant (e.g., 50% / 50% mix with distilled water)
Oil Type:
API CG-4 or CH-4, SAE 15W-40 (Consult manual for exact specification and viscosity based on ambient temperature).
Type:
Komatsu Hydrostatic Transmission (HST) with variable speed control.
Optional Features:
N/A (HST is standard for this model series)
Control:
Single-lever joystick control for forward, reverse, and speed selection.
Fluid Type:
Komatsu genuine transmission oil or equivalent DEXRON III / MERCON.
Overall Length:
Approx. 3.9 meters (12.8 ft) without blade/ripper
Overall Width:
Approx. 1.7 meters (5.6 ft) (standard track gauge)
Overall Height:
Approx. 2.5 meters (8.2 ft) to top of cab/ROPS
Operating Weight:
Approx. 4,500 - 5,000 kg (9,900 - 11,000 lbs), depending on configuration.
Ground Pressure:
Approx. 0.32 kg/cm² (4.5 psi) with standard shoes
Track Gauge:
Approx. 1370 mm (53.9 in)
Track Width:
Standard: 300 mm (11.8 in); Optional: 350 mm (13.8 in)
Ground Clearance:
Approx. 300 mm (11.8 in) (Varies with track wear and track tension)
Safety Features:
ROPS (Roll-Over Protective Structure) and FOPS (Falling Object Protective Structure) compliant cab/structure for operator safety.
Active Safety:
Parking brake, hydrostatic transmission with dynamic braking effect, emergency stop capability.
Passive Safety:
Operator seatbelt, guarded moving parts, safety interlocks on access panels and controls.
Infotainment System:
N/A (Basic operator interface for functionality and diagnostics, no traditional infotainment)
Assistance Features:
Hydrostatic transmission offers ease of operation and precise control, eliminating complex gear shifting. Automatic engine idle control (if equipped).
Connectivity Features:
N/A (No modern connectivity features like Bluetooth or Wi-Fi are standard on this model).
Diagnostic Tools:
The manual provides detailed diagnostic procedures for the engine, hydraulic system, and HST, using visual checks, pressure testing, and component analysis rather than electronic scan tools.
Engine Oil Change:
Every 250 hours or annually, whichever comes first (Consult manual for exact interval).
Hydraulic Oil Change:
Every 1000 hours or annually (Consult manual for exact interval).
Air Filter Replacement:
Inspect daily, replace as needed based on operating conditions and restriction indicator.
Hydraulic Oil Spec:
Komatsu genuine hydraulic oil or equivalent (e.g., ISO VG 46 or 68 depending on application, confirm with manual).
Coolant Capacity:
Approx. 13 Liters (3.4 US gal) (Verify in manual)
Transmission Oil Capacity:
Approx. 28 Liters (7.4 US gal) (Verify in manual)
Engine Oil Capacity:
Approx. 9.5 Liters (2.5 US gal) (Verify in manual)
Common Wear Items:
Undercarriage components (track chains, rollers, idlers, sprockets), hydraulic hoses and seals, engine filters, HST control linkage wear.
Potential Problems:
Overheating due to blocked radiator fins, hydrostatic transmission control issues, wear on pivot points and pins.
Greasing Schedule:
Daily lubrication of track rollers, carrier rollers, idlers, and pivot points. Weekly greasing of blade/ripper linkages. Refer to manual for precise schedule and grease type.
Heritage:
Komatsu is a globally recognized manufacturer of construction and mining equipment, known for its durable and reliable machinery. The D20 series represents their commitment to compact yet powerful dozers.
Evolution:
The D20 series, including the -5 generation, evolved from earlier models, incorporating advancements in hydrostatic transmission technology, improved operator comfort, and enhanced engine efficiency and emissions control.
Production Period:
Mid-1990s to early 2000s (typical production timeframe for the -5 generation).
Manufacturing Location:
Primarily Japan (Komatsu manufacturing facilities)
Industry Awards:
N/A (Specific awards for this model are not typically advertised; Komatsu as a brand is recognized for reliability and innovation in heavy equipment).
Durability Ratings:
Known for robust construction and longevity in demanding work environments. Komatsu products generally receive high ratings for reliability and uptime.
Certifications:
Meets relevant industry standards for safety (e.g., ROPS/FOPS compliance) and emissions depending on the market of sale and manufacturing year.
