Komatsu D275A-2 Bulldozer Repair Manual SEBM000207 PDF Download

Description

KOMATSU D275A-2 BULLDOZER SHOP MANUAL SEBM000207 – PDF DOWNLOAD

FILE DETAILS:

KOMATSU D275A-2 BULLDOZER SHOP MANUAL SEBM000207 – PDF DOWNLOAD

Language : English
Pages : 744
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

KOMATSU D275A-2 BULLDOZER SHOP MANUAL SEBM000207 – PDF DOWNLOAD

MAIN MENU................................................................................................................................................  0
COVER....................................................................................................................................................  1
CONTENTS.................................................................................................................................................  2
FOREWARD.................................................................................................................................................  6
	FOREWARD.............................................................................................................................................  8
	HOW TO BE READ THE SHOP MANUAL.......................................................................................................................  9
	HOISTING INSTRUCTIONS................................................................................................................................ 10
	METHOD OF DIASSEMBLING, CONNEXTING PUSH-PULL TYPE COUPLER............................................................................................ 11
	COATING MATERIALS.................................................................................................................................... 13
	STANDARD TIGHENING TORQUE............................................................................................................................ 15
	ELECTRIC WIRE........................................................................................................................................ 18
	CONVERSION TABLE..................................................................................................................................... 19
	UNITS................................................................................................................................................ 25
01 GENERAL............................................................................................................................................... 26
	GENERAL ASSEMBLY DRAWING ............................................................................................................................ 27
	SPECIFICATIONS ...................................................................................................................................... 28
	WEIGHT TABLE ........................................................................................................................................ 33
	LIST OF LUBRICANT  AND WATER ........................................................................................................................ 35
10 STRUCTURE AND FUNCTION................................................................................................................................ 36
	GENERAL ............................................................................................................................................. 37
	POWER TRAIN.......................................................................................................................................... 38
	POWER TRAIN UNIT..................................................................................................................................... 39
	POWER TRAIN UNIT MOUNT............................................................................................................................... 40
	POWER TRAIN PIPING................................................................................................................................... 41
	POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM................................................................................................................ 42
	DAMPER AND UNIVERSAL JOINT........................................................................................................................... 43
	TORQUE CONVERTER - PTO............................................................................................................................... 45
	TORQUE CONVERTER VALVE............................................................................................................................... 49
	TRANSMISSION ........................................................................................................................................ 59
	TRANSMISSION CONTROL ................................................................................................................................ 64
	TRANSMISSION CONTROL VALVE .......................................................................................................................... 65
	TRANSMISSION LUBRICATION RELIEF VALVE ............................................................................................................... 72
	SCAVENGING PUMP ..................................................................................................................................... 73
	OIL STRAINER ........................................................................................................................................ 74
	POWER TRAIN OIL FILTER AND LUBRICATION OIL FILTER ................................................................................................... 75
	STEERING UNIT ....................................................................................................................................... 76
	TRANSFER, BEVEL PINION .............................................................................................................................. 78
	BEVEL GEAR, STEERING CLUTCH AND STEERING BRAKE....................................................................................................... 79
	STEERING CONTROL .................................................................................................................................... 83
	STEERING CONTROL  VALVE ............................................................................................................................. 84
	FINAL DRIVE ......................................................................................................................................... 91
	MAIN FRAME........................................................................................................................................... 94
	TRACK GROUP.......................................................................................................................................... 95
	RECOIL SPRING ....................................................................................................................................... 96
	SUSPENSION .......................................................................................................................................... 97
	HYDRAULIC PIPING.....................................................................................................................................102
		BLADE............................................................................................................................................102
		VARIABLE MULTIPLE SHANK RIPPER...................................................................................................................103
		VARIABLE GIANT RIPPER............................................................................................................................104
	HYDRAULIC CONTROL ...................................................................................................................................105
		BLADE CONTROL....................................................................................................................................105
		BLADE CONTROL (For dual tilt dozer)..............................................................................................................106
		RIPPER CONTROL...................................................................................................................................107
	HYDRAULIC CIRCUIT SYSTEM ............................................................................................................................108
	HYDRAULIC CIRCUIT DIAGRAM............................................................................................................................109
	HYDRAULIC TANK ......................................................................................................................................111
	BLADE LIFT CONTROL VALVE ............................................................................................................................112
	BLADE TILT CONTROL AND RIPPER LOW VALVE .............................................................................................................116
	RIPPER HIGH VALVE ...................................................................................................................................118
	RIPPER TILT SUCTION VALVE ...........................................................................................................................120
	PISTON VALVE.........................................................................................................................................137
	QUICK DROP VALVE ....................................................................................................................................138
	CYLINDER STAY .......................................................................................................................................139
	SEMI U-DOZER ........................................................................................................................................140
	RIPPER...............................................................................................................................................142
		VARIABLE MULTIPLE SHANK RIPPER...................................................................................................................142
		VARIABLE GIANT RIPPER............................................................................................................................144
	PIN PULLER SOLENOID VALVE............................................................................................................................146
	ELECTRICAL CIRCUIT DIAGRAM...........................................................................................................................148
		CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2).........................................................................................................148
		CAB ELECTRICAL CIRCUIT DIAGRAM...................................................................................................................154
		AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM.......................................................................................................156
	EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM) .........................................................................................................168
	APS CONTROL SYSTEM...................................................................................................................................182
	TORQUE CONVERTER LOCK-UP CONTROL SYSTEM .............................................................................................................186
	MACHINE MONITOR SYSTEM (WITH SSC SYSTEM).............................................................................................................189
	MODEL SELECTION SYSTEM...............................................................................................................................193
	ENGINE CONTROL SYSTEM................................................................................................................................202
	ELPC CONTROLLER......................................................................................................................................203
	ELPC ACTUATOR........................................................................................................................................205
	TORQUE CONVERTER LOCK-UP CONTROL SYSTEM..............................................................................................................212
20 TESTING AND ADJUSTING.................................................................................................................................214
	STANDARD VALUE TABLE FOR ENGINE .....................................................................................................................215
	STANDARD VALUE TABLE FOR CHASSIS ....................................................................................................................217
	STANDARD VALUE TABLE FOR ELECTRICAL JUDGEMENT........................................................................................................223
	TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING............................................................................................225
	TESTING AND ADJUSTING BELT TENSION...................................................................................................................226
	ADJUSTING VALVE CLEARANCE............................................................................................................................228
	MEASURING COMPRESSION PRESSURE.......................................................................................................................229
	MEASURING BLOWBY.....................................................................................................................................230
	ADJUSTING FUEL INJECTION TIMING .....................................................................................................................231
	MEASURING EXHAUST COLOR .............................................................................................................................234
	MEASURING ENGINE OIL PRESSURE .......................................................................................................................235
	MEASURING ENGINE SPEED  .............................................................................................................................235
	MEASURING BOOST PRESSURE ............................................................................................................................236
	MEASURING EXHAUST TEMPERATURE .......................................................................................................................237
	ADJUSTMENT OF FUEL CONTROL LINKAGE ..................................................................................................................238
	ADJUSTMENT OF FUEL CONTROL LINKAGE (WITH SSC SYSTEM).................................................................................................240
	ADJUSTMENT OF GEAR SHIFT LEVER LINKAGE ..............................................................................................................244
	ADJUSTMENT OF STEERING CLUTCH LINKAGE ...............................................................................................................247
	ADJUSTMENT OF BRAKE PEDAL LINKAGE ...................................................................................................................249
	ADJUSTMENT OF WORK EQUIPMENT CONTROL LINKAGE  .......................................................................................................251
	ADJUSTING CLEARANCE OF IDLER ........................................................................................................................255
	MEASURING SPEED AT TORQUE CONVERTER STALL............................................................................................................256
	MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL) ......................................................................257
	MEASURING POWER TRAIN OIL PRESSURE...................................................................................................................258
	TESTING  AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE...........................................................................................261
	BLEEDING AIR FROM HYDRAULIC CYLINDER   ..............................................................................................................262
	MEASURING LEAKAGE INSIDE CYLINDER....................................................................................................................263
	CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER ...................................................................................264
	PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE .............................................................................................265
	PROCEDURE FOR TESTING SENSORS .......................................................................................................................266
	TESTING AND ADJUSTING ELPC VALVE POTENTIOMETER (WITH SSC SYSTEM).....................................................................................269
	TROUBLESHOOTING......................................................................................................................................271
		POINTS TO REMEMBER WHEN TROUBLESHOOTING .........................................................................................................272
		SEQUENCE OF EVENTS IN TROUBLESHOOTING ...........................................................................................................273
		PRECAUTIONS WHEN CARRYING OUT MAINTENANCE........................................................................................................274
		HANDLING CONNECTORS .............................................................................................................................281
		CHECKS  BEFORE TROUBLESHOOTING  .................................................................................................................282
		METHOD OF USING MATRIX TROUBLESHOOTING CHART ....................................................................................................283
		METHOD OF USING  TROUBLESHOOTING CHARTS .........................................................................................................287
		 TYPE OF CONNECTOR AND POSITION OF INSTALLATION  ................................................................................................289
		CONNECTOR POSITION DRAWING.......................................................................................................................291
		CONNECTION TABLE FOR CONNECTOR...................................................................................................................292
		ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM......................................................................................................300
		TROUBLESHOOTING OF ENGINE........................................................................................................................310
			S-1 Starting performance is poor (Starting always takes time)................................................................................311
			S-2 Engine does not start....................................................................................................................312
			S-3 Engine does not pick up smoothly (Follow-up is poor).....................................................................................315
			S-4 Engine stops during operations...........................................................................................................316
			S-5 Engine does not rotate smoothly (hunting)................................................................................................317
			S-6 Engine lacks output (no power)...........................................................................................................318
			S-7 Exhaust smoke is black (incomplete combustion)...........................................................................................319
			S-8 Oil consumption is excessive (or exhaust smoke is blue)..................................................................................320
			S-9 Oil becomes contaminated quickly.........................................................................................................321
			S-10 Fuel consumption is excessive...........................................................................................................322
			S-11 Oil is in cooling water, or water spurts back, or water level goes down.................................................................323
			S-12 Oil pressure lamp lights up (drop in oil pressure)......................................................................................324
			S-13 Oil level rises.........................................................................................................................325
			S-14 Water temperature becomes too high (overheating)........................................................................................326
			S-15 Abnormal noise is made..................................................................................................................327
			S-16 Vibration is excessive..................................................................................................................328
		TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM..................................................................................................329
			TABLE OF FAILURE MODES AND CAUSES............................................................................................................330
			H-1 Brakes do not work.......................................................................................................................331
			H-2 Machine does not turn. (Machine can travel only in a straight line.).....................................................................332
			H-3 There is travel deviation................................................................................................................333
			H-4 Machine turns only in one direction (lever operated).....................................................................................334
			H-5 Time lag is excessive....................................................................................................................335
			H-6 Machine travels only in one direction (forward or in reverse)............................................................................335
			H-7 Machine does not move. (2nd, 3rd engine is running)......................................................................................336
			H-8 Machine does not move in any speed range.................................................................................................338
			H-9 Torque converter oil temperature is high.................................................................................................340
			H-10 Abnormal noise from around hydraulic pump...............................................................................................342
			H-11 Blade RAISE speed slow or work equipment lacks power....................................................................................342
			H-12 Ripper lift speed slow, or lacks power..................................................................................................344
			H-13 Excessive hydraulic drift of blade......................................................................................................345
			H-14 Excessive hydraulic drift of ripper.....................................................................................................345
			H-15 Torque converter lock-up does not work..................................................................................................346
			H-16 Pin-puller cylinder does not work.......................................................................................................346
		TROUBLESHOOTING OF ELECTRICAL SYSTEM.............................................................................................................347
			E-1 Pin puller cylinder does not work (For giant ripper).....................................................................................348
			E-2 Preheating fuse No. 11 is blown (Serial No. : 10001-10167)...............................................................................349
			E-3 Defective  operation of APS (Serial No. : 10168 and up)..................................................................................350
				a) Even when panel preheating switch is pressed, the APS pilot on the monitor panel does not light up....................................350
				b) When panel preheating switch in ON, the APS pilot on the monitor panel lights up, but it does not go out within the range of .........352
				c) Approx. 80 seconds after panel preheating switch is turned ON, APS pilot goes out, but starting performance is poor glow plug.........353
				d) The engine can be started with the APS, but when the starting motor stops, the engine stops also......................................355
				e) APS does not stop.....................................................................................................................356
			E-3 Related electrical circuit diagram.......................................................................................................357
				a) APS pilot on monitor panel does not light up when preheating switch on panel is pressed...............................................358
				b) APS pilot on monitor panel does not go out even when more than 12 seconds has passed after lighting up................................361
					b-1. APS pilot stays lighted up (glow plug system short circuited)...................................................................361
					b-2. APS pilot flashes (disconnection in APS water temperature sensor)...............................................................361
				c) APS pilot on monitor panel lights up when starting switch is at START (short circuit with ground in nozzle system)....................362
				d) APS does not work (when there is no abnormality in Items a) - c) for Defective operation of APS)......................................363
					d-1. Disconnection in C signal input system..........................................................................................363
					d-2. Disconnection in glow plug system...............................................................................................365
					d-3. Disconnection in nozzle system..................................................................................................366
				e) APS does not stop even when water temperature is above 20°C (short circuit with ground in APS water temperature sensor system.........367
			E-4 Even when the light switch is turned ON, the lamps do not light up  .....................................................................369
				a) Head lamp switch .....................................................................................................................369
				b) Rear lamp switch......................................................................................................................370
				c) Working lamp switch ..................................................................................................................371
			E-5 Even when the light switch is turned OFF, the lamps do not go out .......................................................................372
				a) Head lamp switch......................................................................................................................372
				b) Rear lamp switch .....................................................................................................................372
				c) Working lamp switch...................................................................................................................372
			E-6 Panel switch does not work. - Abnormality in panel switch power source   ................................................................373
		TROUBLESHOOTING OF ELECTRICAL SYSTEM (WITH SSC SYSTEM)...........................................................................................375
			Table of failure modes and causes (mode selection electronic system).........................................................................376
			E-S1 Torque converter lock-up does not work (lock-up display lamp does not light up).........................................................378
			E-S2 Torque coverter lock-up display is abnormal.............................................................................................381
				Lock-up display lamp does not go out.....................................................................................................381
				Lock-up display lamp does not go out.....................................................................................................381
			E-S3 Blown fuse no.8 of torque converter lock-up relay inside relay box......................................................................382
			E-S4 Mode does not switch when economy mode is pressed (monitor panel LED is normal).........................................................383
			E-S5 Reverse slow is not actuated when REVERSE slow switch is pressed (monitor panel LED is normal)..........................................384
			E-S6 Shoe slip control is not actuated when shoe slip control switch is pressed (monitor panel LED is normal)................................385
			E-S7 Selected level does not change when rockbed selection mode switch is pressed (monitor panel LED is normal)..............................386
			E-S8 Engine cannot be controlled, engine stalls, engine cannot be started....................................................................387
			E-S9 Shoe slip is not detected when shoe slip control is ON..................................................................................388
			E-S10 Starting modulation does not work when shoe slip control is ON.........................................................................389
			E-S11 There is no up/down of drawbar pull by using ripper lever when shoe slip control is ON.................................................389
			E-S12 Abnormality in ripper UP, DOWN, TILT signal, REVERSE signal............................................................................390
		TROUBLESHOOTING OF MACHINE MONITOR SYSTEM........................................................................................................393
			Table of failure modes and causes (machine monitor, mode selection switch)...................................................................394
			M-1 No display appears on the monitor panel when the starting switch is ON...................................................................396
			M-2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out.....................................................396
			M-3 When starting switch is ON (engine stopped), CHECK items show abnormality  (Liquid levels is normal for check items before starting) ....397
				a) Abnormality in coolant level..........................................................................................................397
				b) Abnormality in engine oil level.......................................................................................................398
			M-4 Abnormality in preheating................................................................................................................399
				a) Preheating monitor does not light UP..................................................................................................399
				b) Preheating monitor stays lighted up...................................................................................................399
			M-5 When starting switch is ON and engine is started, CAUTION items flash  (When there is no abnormality in the CHECK items or engine) ......400
				a) Charge level flashes .................................................................................................................400
				b) Engine oil pressure flashes ..........................................................................................................400
				c) Coolant level flashes ................................................................................................................400
				d) Coolant temperature flashes ..........................................................................................................400
				e) Torque converter oil temperature flashes .............................................................................................401
				f) Hydraulic oil temperature flashes.....................................................................................................401
				g) Electronic system abnormality flashes.................................................................................................404
			M-6 Abnormality in buzzer ...................................................................................................................405
				a) CAUTION items are flashing, but buzzer does not sound. ...............................................................................405
				b) No abnormal display is given on monitor, but buzzer sound. ...........................................................................405
			M-7  Abnormality in warning lamp ............................................................................................................406
				a) CAUTION items are flashing,  but lamps do not flash...................................................................................406
				b) No abnormal display is given on  monitor, but lamp lights up .........................................................................406
			M-8 Abnormality in gauge ....................................................................................................................407
				a) Abnormality in coolant temperature gauge .............................................................................................407
				b) Abnormality in torque converter oil  temperature gauge ...............................................................................408
				c) Abnormality in fuel level gauge.......................................................................................................409
			M-9 Service meter does not move after engine is started .....................................................................................410
			M-10 Panel lighting for monitor panel does not light up (Liquid crystal display is normal) ..................................................411
			M-11 After starting switch is turned ON, display LED does not light up even when mode selection switch is pressed............................412
			M-12 LED on panel is normal, but there is no output from mode selection switch module........................................................413
			M-13 LED on mode selection switch panel does not flash when lighting switch is ON............................................................414
			M-14 Defective initial setting...............................................................................................................415
				Initial setting cannot be made when initial set switch is ON.............................................................................415
				Initial setting is made when initial set switch is OFF...................................................................................415
		TROUBLESHOOTING OF SHOE SLIP CONTROLLER, ELPC CONTROLLER SYSTEM (G MODE).........................................................................416
			G-1 (Abnormality in engine) is displayed.....................................................................................................417
			G-2 (Abnormality in acceleration sensor power source) is displayed...........................................................................418
			G-3 (Abnormality in torque converter speed sensor) is displayed..............................................................................419
			G-4 (Abnormality in engine speed sensor) is displayed........................................................................................420
			G-5 (Abnormality in acceleration economy mode selection) is displayed........................................................................421
			G-6 (Abnormality in control mode selection) is displayed.....................................................................................422
			G-7 (Abnormality in acceleration sensor) is displayed........................................................................................423
			G-8 (Abnormality in ripping mode selection) is displayed.....................................................................................424
			G-9 (Abnormality in ELPC controller) is displayed............................................................................................425
			G-10 (Abnormality in sensor power source) is displayed.......................................................................................426
			G-11 (Abnormality in feedback potentiometer) is displayed....................................................................................427
			G-12 (Abnormality in input potentiometer) is displayed.......................................................................................428
			G-13 (Abnormality in shoe slip control command) is displayed.................................................................................429
			G-14 (Disconnection, short circuit in solenoid system) is displayed..........................................................................430
			G-15 (Abnormality in shoe slip controller) is displayed......................................................................................431
			G-16 (Abnormality in power source) is displayed..............................................................................................432
30 DISASSEMBLY AND ASSEMBLY..............................................................................................................................433
	METHOD OF USING MANUAL ..............................................................................................................................435
	PRECAUTIONS WHEN CARRYING OUT OPERATION .............................................................................................................436
	SPECIAL TOOL LIST  ..................................................................................................................................438
	STARTING MOTOR.......................................................................................................................................445
		REMOVAL..........................................................................................................................................445
		INSTALLATION ....................................................................................................................................445
	ALTERNATOR...........................................................................................................................................446
		REMOVAL..........................................................................................................................................446
		INSTALLATION.....................................................................................................................................446
	ENGINE OIL COOLER....................................................................................................................................448
		REMOVAL..........................................................................................................................................448
		INSTALLATION ....................................................................................................................................448
	TORQUE CONVERTER OIL COOLER..........................................................................................................................449
		REMOVAL..........................................................................................................................................449
		INSTALLATION.....................................................................................................................................449
	FUEL INJECTION PUMP..................................................................................................................................451
		REMOVAL..........................................................................................................................................451
		INSTALLATION ....................................................................................................................................451
	WATER PUMP...........................................................................................................................................453
		REMOVAL..........................................................................................................................................453
		INSTALLATION ....................................................................................................................................453
	TURBOCHARGER.........................................................................................................................................455
		REMOVAL..........................................................................................................................................455
		INSTALLATION ....................................................................................................................................455
	NOZZLE HOLDER........................................................................................................................................456
		REMOVAL..........................................................................................................................................456
		INSTALLATION.....................................................................................................................................456
	CYLINDER HEAD........................................................................................................................................457
		REMOVAL..........................................................................................................................................457
		INSTALLATION.....................................................................................................................................461
	FUEL TANK ...........................................................................................................................................463
		REMOVAL..........................................................................................................................................463
		INSTALLATION ....................................................................................................................................463
	RADIATOR AND FRONT GUARD.............................................................................................................................464
		TURNING OVER.....................................................................................................................................464
		INSTALLATION ....................................................................................................................................464
	RADIATOR ............................................................................................................................................465
		REMOVAL..........................................................................................................................................465
		INSTALLATION.....................................................................................................................................465
	RADIATOR GUARD.......................................................................................................................................466
		REMOVAL..........................................................................................................................................466
		INSTALLATION.....................................................................................................................................468
	ENGINE ..............................................................................................................................................469
		REMOVAL..........................................................................................................................................469
		INSTALLATION ....................................................................................................................................472
	DAMPER ..............................................................................................................................................473
		REMOVAL..........................................................................................................................................473
		INSTALLATION ....................................................................................................................................474
		DISASSEMBLY .....................................................................................................................................475
		ASSEMBLY ........................................................................................................................................476
	POWER TRAIN UNIT.....................................................................................................................................478
		REMOVAL..........................................................................................................................................478
		INSTALLATION.....................................................................................................................................480
		DISCONNECTION....................................................................................................................................481
		CONNECTION.......................................................................................................................................483
	PTO, TORQUE CONVERTER................................................................................................................................484
		DISCONNECTION....................................................................................................................................484
		CONNECTION.......................................................................................................................................485
	TORQUE CONVERTER.....................................................................................................................................486
		DISASSEMBLY......................................................................................................................................486
		ASSEMBLY ........................................................................................................................................491
	PTO..................................................................................................................................................497
		DISASSEMBLY......................................................................................................................................497
		ASSEMBLY.........................................................................................................................................501
	TORQFLOW TRANSMISSION................................................................................................................................506
		DISASSEMBLY......................................................................................................................................506
		ASSEMBLY ........................................................................................................................................516
	STEERING CASE........................................................................................................................................529
		DISASSEMBLY......................................................................................................................................529
		ASSEMBLY ........................................................................................................................................532
	STEERING CLUTCH, BRAKE ..............................................................................................................................538
		DISASSEMBLY......................................................................................................................................538
		ASSEMBLY ........................................................................................................................................542
	TRANSFER GEAR HOUSING ...............................................................................................................................546
		DISASSEMBLY......................................................................................................................................546
		ASSEMBLY ........................................................................................................................................548
	TORQUE CONVERTER VALVE...............................................................................................................................551
		REMOVAL..........................................................................................................................................551
		INSTALLATION ....................................................................................................................................551
		DISASSEMBLY......................................................................................................................................552
		ASSEMBLY  .......................................................................................................................................554
	TRANSMISSION CONTROL VALVE ..........................................................................................................................555
		REMOVAL..........................................................................................................................................555
		INSTALLATION.....................................................................................................................................555
		DISASSEMBLY .....................................................................................................................................556
		ASSEMBLY ........................................................................................................................................557
	STEERING CONTROL VALVE...............................................................................................................................558
		REMOVAL..........................................................................................................................................558
		INSTALLATION.....................................................................................................................................558
		DISASSEMBLY .....................................................................................................................................559
		ASSEMBLY.........................................................................................................................................559
	SCAVENGING PUMP......................................................................................................................................561
		REMOVAL..........................................................................................................................................561
		INSTALLATION ....................................................................................................................................561
	POWER TRAIN PUMP.....................................................................................................................................562
		REMOVAL..........................................................................................................................................562
		INSTALLATION.....................................................................................................................................562
	FINAL DRIVE..........................................................................................................................................563
		REMOVAL..........................................................................................................................................563
		INSTALLATION ....................................................................................................................................564
		DISASSEMBLY .....................................................................................................................................565
		ASSEMBLY ........................................................................................................................................573
	TRACK FRAME..........................................................................................................................................585
		REMOVAL..........................................................................................................................................585
		INSTALLATION ....................................................................................................................................585
	IDLER YOKE ..........................................................................................................................................586
		REMOVAL..........................................................................................................................................586
		INSTALLATION ....................................................................................................................................588
	RECOIL SPRING .......................................................................................................................................589
		REMOVAL..........................................................................................................................................589
		INSTALLATION.....................................................................................................................................593
		DISASSEMBLY .....................................................................................................................................594
		ASSEMBLY ........................................................................................................................................594
	IDLER ...............................................................................................................................................596
		REMOVAL..........................................................................................................................................596
		INSTALLATION.....................................................................................................................................596
		DISASSEMBLY......................................................................................................................................597
		ASSEMBLY.........................................................................................................................................598
	TRACK ROLLER.........................................................................................................................................600
		REMOVAL..........................................................................................................................................600
		INSTALLATION ....................................................................................................................................600
		DISASSEMBLY......................................................................................................................................601
		ASSEMBLY.........................................................................................................................................602
	CARRIER ROLLER.......................................................................................................................................603
		REMOVAL..........................................................................................................................................603
		INSTALLATION ....................................................................................................................................603
		DISASSEMBLY......................................................................................................................................604
		ASSEMBLY ........................................................................................................................................605
	TRACK  SHOE .........................................................................................................................................607
		REMOVAL .........................................................................................................................................607
		INSTALLATION.....................................................................................................................................609
		OVERALL DISASSEMBLY .............................................................................................................................610
		OVERALL ASSEMBLY.................................................................................................................................615
		PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.................................................................................................629
		FIELD DISASSEMBLY OF ONE LINK....................................................................................................................630
		FIELD ASSEMBLY OF ONE LINK.......................................................................................................................632
		DISASSEMBLY OF MASTER LINK.......................................................................................................................634
		ASSEMBLY OF MASTER LINK..........................................................................................................................636
	PIVOT SHAFT TWISTING SEAL ...........................................................................................................................639
		REMOVAL..........................................................................................................................................639
		INSTALLATION.....................................................................................................................................639
	PIVOT SHAFT..........................................................................................................................................640
		REMOVAL..........................................................................................................................................640
		INSTALLATION ....................................................................................................................................640
	EQUALIZER BAR........................................................................................................................................641
		REMOVAL..........................................................................................................................................641
		INSTALLATION.....................................................................................................................................643
	EQUALIZER  BAR SIDE BUSHING .........................................................................................................................645
		REMOVAL..........................................................................................................................................645
		INSTALLATION ....................................................................................................................................646
	SUSPENSION CUSHION...................................................................................................................................647
		REMOVAL..........................................................................................................................................647
		INSTALLATION.....................................................................................................................................647
	SEGMENT TOOTH .......................................................................................................................................648
		REMOVAL..........................................................................................................................................648
		INSTALLATION.....................................................................................................................................648
	HYDRAULIC PUMP.......................................................................................................................................649
		REMOVAL..........................................................................................................................................649
		INSTALLATION.....................................................................................................................................649
	BLADE LIFT VALVE.....................................................................................................................................650
		REMOVAL..........................................................................................................................................650
		INSTALLATION ....................................................................................................................................650
		DISASSEMBLY......................................................................................................................................651
		ASSEMBLY.........................................................................................................................................653
	BLADE TILT, RIPPER LOW VALVE.........................................................................................................................655
		REMOVAL..........................................................................................................................................655
		INSTALLATION.....................................................................................................................................655
		DISASSEMBLY......................................................................................................................................656
		ASSEMBLY.........................................................................................................................................658
	RIPPER HIGH VALVE....................................................................................................................................660
		REMOVAL..........................................................................................................................................660
		INSTALLATION.....................................................................................................................................660
		DISASSEMBLY......................................................................................................................................661
		ASSEMBLY.........................................................................................................................................663
	BLADE LIFT CYLINDER..................................................................................................................................665
		REMOVAL..........................................................................................................................................665
		INSTALLATION.....................................................................................................................................665
	BLADE TILT CYLINDER..................................................................................................................................666
		REMOVAL..........................................................................................................................................666
		INSTALLATION.....................................................................................................................................666
	RIPPER LIFT CYLINDER.................................................................................................................................667
		REMOVAL..........................................................................................................................................667
		INSTALLATION.....................................................................................................................................667
	RIPPER TILT CYLINDER.................................................................................................................................668
		REMOVAL..........................................................................................................................................668
		INSTALLATION.....................................................................................................................................668
	HYDRAULIC CYLINDER...................................................................................................................................669
		DISASSEMBLY......................................................................................................................................669
		ASSEMBLY.........................................................................................................................................671
	WORK EQUIPMENT.......................................................................................................................................674
		REMOVAL..........................................................................................................................................674
		INSTALLATION.....................................................................................................................................675
		DISASSEMBLY......................................................................................................................................676
		ASSEMBLY.........................................................................................................................................678
	RIPPER...............................................................................................................................................679
		DISASSEMBLY......................................................................................................................................679
		ASSEMBLY.........................................................................................................................................680
40 MAINTENANCE STANDARD..................................................................................................................................686
	ENGINE MOUNT ........................................................................................................................................687
	POWER TRAIN MOUNT....................................................................................................................................688
	DAMPER AND UNIVERSAL JOINT ..........................................................................................................................690
	TORQUE CONVERTER.....................................................................................................................................691
	TORQUE CONVERTER VALVE  .............................................................................................................................693
	TRANSMISSION ........................................................................................................................................695
	TRANSMISSION CONTROL VALVE ..........................................................................................................................697
	POWER TRAIN AND LUBRICATING PUMP ....................................................................................................................699
	TRANSFER AND BEVEL PINION............................................................................................................................700
	BEVEL GEAR SHAFT, STEERING CLUTCH AND STEERING BRAKE.................................................................................................701
	STEERING CONTROL VALVE...............................................................................................................................703
	FINAL DRIVE..........................................................................................................................................705
	MAIN FRAME...........................................................................................................................................707
	TRACK  FRAME ........................................................................................................................................709
	RECOIL SPRING........................................................................................................................................711
	IDLER ...............................................................................................................................................713
	TRACK ROLLER ........................................................................................................................................715
	CARRIER ROLLER ......................................................................................................................................717
	TRACK................................................................................................................................................719
	SUSPENSION ..........................................................................................................................................721
	HYDRAULIC PUMP ......................................................................................................................................727
	BLADE LIFT CONTROL VALVE   ..........................................................................................................................728
		MAIN RELIEF VALVE AND SHUTTLE VALVE..............................................................................................................729
	BLADE TILT CONTROL AND RIPPER LOW VALVE .............................................................................................................730
	RIPPER HIGH VALVE ...................................................................................................................................731
	HYDRAULIC CYLINDER...................................................................................................................................732
		BLADE LIFT CYLINDER..............................................................................................................................732
		BLADE TILT CYLINDER..............................................................................................................................732
		RIPPER LIFT CYLINDER.............................................................................................................................732
		RIPPER TILT CYLINDER.............................................................................................................................733
		DUAL TILT CYLINDER...............................................................................................................................734
		PIN PULLER CYLINDER..............................................................................................................................734
	QUICK DROP VALVE ....................................................................................................................................735
	CYLINDER STAY .......................................................................................................................................736
	SEMI U-DOZER ........................................................................................................................................737
		CUTTING EDGE AND END BIT.........................................................................................................................739
	RIPPER...............................................................................................................................................740
		VARIABLE MULTIPLE SHANK RIPPER...................................................................................................................740
		VARIABLE GIANT RIPPER............................................................................................................................742

DESCRIPTION:

KOMATSU D275A-2 BULLDOZER SHOP MANUAL SEBM000207 – PDF DOWNLOAD

FOREWORD
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
In addition, this section may contain hydraulic circuit diagrams, electric maintenance standards. for troubleshooting. circuit diagrams, and maintenance standard
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.

S.S 25/12/24