Komatsu D275A-2 Bulldozer Shop Manual SEBM000207 – PDF DOWNLOAD

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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

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 for troubleshooting. In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
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.

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 PIPING102
BLADE102
VARIABLE MULTIPLE SHANK RIPPER103
VARIABLE GIANT RIPPER104
HYDRAULIC CONTROL 105
BLADE CONTROL105
BLADE CONTROL (For dual tilt dozer)106
RIPPER CONTROL107
HYDRAULIC CIRCUIT SYSTEM 108
HYDRAULIC CIRCUIT DIAGRAM109
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 VALVE137
QUICK DROP VALVE 138
CYLINDER STAY 139
SEMI U-DOZER 140
RIPPER142
VARIABLE MULTIPLE SHANK RIPPER142
VARIABLE GIANT RIPPER144
PIN PULLER SOLENOID VALVE146
ELECTRICAL CIRCUIT DIAGRAM148
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2)148
CAB ELECTRICAL CIRCUIT DIAGRAM154
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM156
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM) 168
APS CONTROL SYSTEM182
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM 186
MACHINE MONITOR SYSTEM (WITH SSC SYSTEM)189
MODEL SELECTION SYSTEM193
ENGINE CONTROL SYSTEM202
ELPC CONTROLLER203
ELPC ACTUATOR205
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM212
20 TESTING AND ADJUSTING214
STANDARD VALUE TABLE FOR ENGINE 215
STANDARD VALUE TABLE FOR CHASSIS 217
STANDARD VALUE TABLE FOR ELECTRICAL JUDGEMENT223
TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING225
TESTING AND ADJUSTING BELT TENSION226
ADJUSTING VALVE CLEARANCE228
MEASURING COMPRESSION PRESSURE229
MEASURING BLOWBY230
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 STALL256
MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL) 257
MEASURING POWER TRAIN OIL PRESSURE258
TESTING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE261
BLEEDING AIR FROM HYDRAULIC CYLINDER 262
MEASURING LEAKAGE INSIDE CYLINDER263
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
TROUBLESHOOTING271
POINTS TO REMEMBER WHEN TROUBLESHOOTING 272
SEQUENCE OF EVENTS IN TROUBLESHOOTING 273
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE274
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 DRAWING291
CONNECTION TABLE FOR CONNECTOR292
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM300
TROUBLESHOOTING OF ENGINE310
S-1 Starting performance is poor (Starting always takes time)311
S-2 Engine does not start312
S-3 Engine does not pick up smoothly (Follow-up is poor)315
S-4 Engine stops during operations316
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 quickly321
S-10 Fuel consumption is excessive322
S-11 Oil is in cooling water, or water spurts back, or water level goes down323
S-12 Oil pressure lamp lights up (drop in oil pressure)324
S-13 Oil level rises325
S-14 Water temperature becomes too high (overheating)326
S-15 Abnormal noise is made327
S-16 Vibration is excessive328
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM329
TABLE OF FAILURE MODES AND CAUSES330
H-1 Brakes do not work331
H-2 Machine does not turn (Machine can travel only in a straight line)332
H-3 There is travel deviation333
H-4 Machine turns only in one direction (lever operated)334
H-5 Time lag is excessive335
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 range338
H-9 Torque converter oil temperature is high340
H-10 Abnormal noise from around hydraulic pump342
H-11 Blade RAISE speed slow or work equipment lacks power342
H-12 Ripper lift speed slow, or lacks power344
H-13 Excessive hydraulic drift of blade345
H-14 Excessive hydraulic drift of ripper345
H-15 Torque converter lock-up does not work346
H-16 Pin-puller cylinder does not work346
TROUBLESHOOTING OF ELECTRICAL SYSTEM347
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 up350
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 plug353
d) The engine can be started with the APS, but when the starting motor stops, the engine stops also355
e) APS does not stop356
E-3 Related electrical circuit diagram357
a) APS pilot on monitor panel does not light up when preheating switch on panel is pressed358
b) APS pilot on monitor panel does not go out even when more than 12 seconds has passed after lighting up361
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 system363
d-2 Disconnection in glow plug system365
d-3 Disconnection in nozzle system366
e) APS does not stop even when water temperature is above 20°C (short circuit with ground in APS water temperature sensor system367
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 switch370
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 switch372
b) Rear lamp switch 372
c) Working lamp switch372
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 abnormal381
Lock-up display lamp does not go out381
Lock-up display lamp does not go out381
E-S3 Blown fuse no8 of torque converter lock-up relay inside relay box382
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 started387
E-S9 Shoe slip is not detected when shoe slip control is ON388
E-S10 Starting modulation does not work when shoe slip control is ON389
E-S11 There is no up/down of drawbar pull by using ripper lever when shoe slip control is ON389
E-S12 Abnormality in ripper UP, DOWN, TILT signal, REVERSE signal390
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM393
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 ON396
M-2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out396
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 level397
b) Abnormality in engine oil level398
M-4 Abnormality in preheating399
a) Preheating monitor does not light UP399
b) Preheating monitor stays lighted up399
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 flashes401
g) Electronic system abnormality flashes404
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 flash406
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 gauge409
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 pressed412
M-12 LED on panel is normal, but there is no output from mode selection switch module413
M-13 LED on mode selection switch panel does not flash when lighting switch is ON414
M-14 Defective initial setting415
Initial setting cannot be made when initial set switch is ON415
Initial setting is made when initial set switch is OFF415
TROUBLESHOOTING OF SHOE SLIP CONTROLLER, ELPC CONTROLLER SYSTEM (G MODE)416
G-1 (Abnormality in engine) is displayed417
G-2 (Abnormality in acceleration sensor power source) is displayed418
G-3 (Abnormality in torque converter speed sensor) is displayed419
G-4 (Abnormality in engine speed sensor) is displayed420
G-5 (Abnormality in acceleration economy mode selection) is displayed421
G-6 (Abnormality in control mode selection) is displayed422
G-7 (Abnormality in acceleration sensor) is displayed423
G-8 (Abnormality in ripping mode selection) is displayed424
G-9 (Abnormality in ELPC controller) is displayed425
G-10 (Abnormality in sensor power source) is displayed426
G-11 (Abnormality in feedback potentiometer) is displayed427
G-12 (Abnormality in input potentiometer) is displayed428
G-13 (Abnormality in shoe slip control command) is displayed429
G-14 (Disconnection, short circuit in solenoid system) is displayed430
G-15 (Abnormality in shoe slip controller) is displayed431
G-16 (Abnormality in power source) is displayed432
30 DISASSEMBLY AND ASSEMBLY433
METHOD OF USING MANUAL 435
PRECAUTIONS WHEN CARRYING OUT OPERATION 436
SPECIAL TOOL LIST 438
STARTING MOTOR445
REMOVAL445
INSTALLATION 445
ALTERNATOR446
REMOVAL446
INSTALLATION446
ENGINE OIL COOLER448
REMOVAL448
INSTALLATION 448
TORQUE CONVERTER OIL COOLER449
REMOVAL449
INSTALLATION449
FUEL INJECTION PUMP451
REMOVAL451
INSTALLATION 451
WATER PUMP453
REMOVAL453
INSTALLATION 453
TURBOCHARGER455
REMOVAL455
INSTALLATION 455
NOZZLE HOLDER456
REMOVAL456
INSTALLATION456
CYLINDER HEAD457
REMOVAL457
INSTALLATION461
FUEL TANK 463
REMOVAL463
INSTALLATION 463
RADIATOR AND FRONT GUARD464
TURNING OVER464
INSTALLATION 464
RADIATOR 465
REMOVAL465
INSTALLATION465
RADIATOR GUARD466
REMOVAL466
INSTALLATION468
ENGINE 469
REMOVAL469
INSTALLATION 472
DAMPER 473
REMOVAL473
INSTALLATION 474
DISASSEMBLY 475
ASSEMBLY 476
POWER TRAIN UNIT478
REMOVAL478
INSTALLATION480
DISCONNECTION481
CONNECTION483
PTO, TORQUE CONVERTER484
DISCONNECTION484
CONNECTION485
TORQUE CONVERTER486
DISASSEMBLY486
ASSEMBLY 491
PTO497
DISASSEMBLY497
ASSEMBLY501
TORQFLOW TRANSMISSION506
DISASSEMBLY506
ASSEMBLY 516
STEERING CASE529
DISASSEMBLY529
ASSEMBLY 532
STEERING CLUTCH, BRAKE 538
DISASSEMBLY538
ASSEMBLY 542
TRANSFER GEAR HOUSING 546
DISASSEMBLY546
ASSEMBLY 548
TORQUE CONVERTER VALVE551
REMOVAL551
INSTALLATION 551
DISASSEMBLY552
ASSEMBLY 554
TRANSMISSION CONTROL VALVE 555
REMOVAL555
INSTALLATION555
DISASSEMBLY 556
ASSEMBLY 557
STEERING CONTROL VALVE558
REMOVAL558
INSTALLATION558
DISASSEMBLY 559
ASSEMBLY559
SCAVENGING PUMP561
REMOVAL561
INSTALLATION 561
POWER TRAIN PUMP562
REMOVAL562
INSTALLATION562
FINAL DRIVE563
REMOVAL563
INSTALLATION 564
DISASSEMBLY 565
ASSEMBLY 573
TRACK FRAME585
REMOVAL585
INSTALLATION 585
IDLER YOKE 586
REMOVAL586
INSTALLATION 588
RECOIL SPRING 589
REMOVAL589
INSTALLATION593
DISASSEMBLY 594
ASSEMBLY 594
IDLER 596
REMOVAL596
INSTALLATION596
DISASSEMBLY597
ASSEMBLY598
TRACK ROLLER600
REMOVAL600
INSTALLATION 600
DISASSEMBLY601
ASSEMBLY602
CARRIER ROLLER603
REMOVAL603
INSTALLATION 603
DISASSEMBLY604
ASSEMBLY 605
TRACK SHOE 607
REMOVAL 607
INSTALLATION609
OVERALL DISASSEMBLY 610
OVERALL ASSEMBLY615
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS629
FIELD DISASSEMBLY OF ONE LINK630
FIELD ASSEMBLY OF ONE LINK632
DISASSEMBLY OF MASTER LINK634
ASSEMBLY OF MASTER LINK636
PIVOT SHAFT TWISTING SEAL 639
REMOVAL639
INSTALLATION639
PIVOT SHAFT640
REMOVAL640
INSTALLATION 640
EQUALIZER BAR641
REMOVAL641
INSTALLATION643
EQUALIZER BAR SIDE BUSHING 645
REMOVAL645
INSTALLATION 646
SUSPENSION CUSHION647
REMOVAL647
INSTALLATION647
SEGMENT TOOTH 648
REMOVAL648
INSTALLATION648
HYDRAULIC PUMP649
REMOVAL649
INSTALLATION649
BLADE LIFT VALVE650
REMOVAL650
INSTALLATION 650
DISASSEMBLY651
ASSEMBLY653
BLADE TILT, RIPPER LOW VALVE655
REMOVAL655
INSTALLATION655
DISASSEMBLY656
ASSEMBLY658
RIPPER HIGH VALVE660
REMOVAL660
INSTALLATION660
DISASSEMBLY661
ASSEMBLY663
BLADE LIFT CYLINDER665
REMOVAL665
INSTALLATION665
BLADE TILT CYLINDER666
REMOVAL666
INSTALLATION666
RIPPER LIFT CYLINDER667
REMOVAL667
INSTALLATION667
RIPPER TILT CYLINDER668
REMOVAL668
INSTALLATION668
HYDRAULIC CYLINDER669
DISASSEMBLY669
ASSEMBLY671
WORK EQUIPMENT674
REMOVAL674
INSTALLATION675
DISASSEMBLY676
ASSEMBLY678
RIPPER679
DISASSEMBLY679
ASSEMBLY680
40 MAINTENANCE STANDARD686
ENGINE MOUNT 687
POWER TRAIN MOUNT688
DAMPER AND UNIVERSAL JOINT 690
TORQUE CONVERTER691
TORQUE CONVERTER VALVE 693
TRANSMISSION 695
TRANSMISSION CONTROL VALVE 697
POWER TRAIN AND LUBRICATING PUMP 699
TRANSFER AND BEVEL PINION700
BEVEL GEAR SHAFT, STEERING CLUTCH AND STEERING BRAKE701
STEERING CONTROL VALVE703
FINAL DRIVE705
MAIN FRAME707
TRACK FRAME 709
RECOIL SPRING711
IDLER 713
TRACK ROLLER 715
CARRIER ROLLER 717
TRACK719
SUSPENSION 721
HYDRAULIC PUMP 727
BLADE LIFT CONTROL VALVE 728
MAIN RELIEF VALVE AND SHUTTLE VALVE729
BLADE TILT CONTROL AND RIPPER LOW VALVE 730
RIPPER HIGH VALVE 731
HYDRAULIC CYLINDER732
BLADE LIFT CYLINDER732
BLADE TILT CYLINDER732
RIPPER LIFT CYLINDER732
RIPPER TILT CYLINDER733
DUAL TILT CYLINDER734
PIN PULLER CYLINDER734
QUICK DROP VALVE 735
CYLINDER STAY 736
SEMI U-DOZER 737
CUTTING EDGE AND END BIT739
RIPPER740
VARIABLE MULTIPLE SHANK RIPPER740
VARIABLE GIANT RIPPER742

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S.M 12/12/24