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Komatsu D275A-5R Crawler Bulldozer Shop Manual SEN02158-12 – PDF DOWNLOAD
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Description
Komatsu D275A-5R Crawler Bulldozer Shop Manual SEN02158-12
FILE DETAILS:
Komatsu D275A-5R Crawler Bulldozer Shop Manual SEN02158-12
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D275A-5R
Serial Number: 35001 and up
Book Code: SEN02158-12
Language: English
Pages: 1459
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D275A-5R Crawler Bulldozer Shop Manual SEN02158-12
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu D275A-5R Crawler Bulldozer Shop Manual SEN02158-12
COVER .............................................................................................................................. 1 00 Index and foreword............................................................................................................... 0 Index........................................................................................................................... 3 Composition of shop manual.................................................................................................. 4 Table of contents........................................................................................................... 6 Foreword and general information................................................................................................ 19 Safety notice............................................................................................................... 20 How to read the shop manual................................................................................................. 25 Explanation of terms for maintenance standard............................................................................... 27 Handling of electric equipment and hydraulic component...................................................................... 29 Handling of connectors newly used for engines............................................................................... 38 How to read electric wire code.............................................................................................. 41 Precautions when carrying out operation..................................................................................... 44 Method of disassembling and connecting push-pull type coupler............................................................... 47 Standard tightening torque table............................................................................................ 50 Conversion table............................................................................................................ 54 01 Specification.................................................................................................................... 0 Specification and technical data................................................................................................ 61 Specefication dimension drawings............................................................................................ 62 Specifications.............................................................................................................. 64 Weight table................................................................................................................ 76 Table of fuel, coolant and lubricants....................................................................................... 80 10 Structure, function and maintenance standard..................................................................................... 0 Engine and cooling system....................................................................................................... 83 Engine mount................................................................................................................ 84 Cooling system.............................................................................................................. 86 Cooling fan pump............................................................................................................ 88 Cooling fan motor........................................................................................................... 96 Power train system, Part 1...................................................................................................... 103 Power train................................................................................................................. 104 Overall drawing of power train unit......................................................................................... 106 Power train hydraulic piping drawing........................................................................................ 110 Damper, universal joint..................................................................................................... 112 Torque converter, PTO....................................................................................................... 114 Torque converter............................................................................................................ 118 Scavenging pump............................................................................................................. 121 Transmission control........................................................................................................ 122 Transmission................................................................................................................ 124 Tranmission ECMV............................................................................................................ 138 Main relief valve and torque convertor relif valve.......................................................................... 144 Power train pump, steering lubrication pump................................................................................. 147 Lubrication relief valve.................................................................................................... 148 Power train system, Part 2...................................................................................................... 151 Steering, brake control..................................................................................................... 152 Bevel gear shaft, steering clutch and brake................................................................................. 154 Steering control valve...................................................................................................... 164 Steering clutch ECMV........................................................................................................ 166 Steering brake ECMV......................................................................................................... 167 Parking brake valve......................................................................................................... 174 Sudden brake prevention valve............................................................................................... 175 Final drive................................................................................................................. 176 Sprocket.................................................................................................................... 182 Undercarriage and frame......................................................................................................... 185 Track frame................................................................................................................. 186 ldler cushiion.............................................................................................................. 190 Idler....................................................................................................................... 194 Track roller................................................................................................................ 196 Track roller bogie.......................................................................................................... 198 Carrier roller.............................................................................................................. 200 Track shoe.................................................................................................................. 202 Main frame.................................................................................................................. 204 Hydraulic system, Part 1........................................................................................................ 215 Work equipment hydraulic piping diagram..................................................................................... 216 PPC control piping diagram.................................................................................................. 220 Work equipment control...................................................................................................... 222 Hydraulic tank.............................................................................................................. 224 Work equipment pump......................................................................................................... 226 Hydraulic system, Part 2........................................................................................................ 243 Control valve............................................................................................................... 244 Operation of control valve.................................................................................................. 254 Self pressure reducing valve................................................................................................ 271 Hydraulic system, Part 3........................................................................................................ 279 PPC valve................................................................................................................... 280 PCCS lever.................................................................................................................. 292 PPC lock valve.............................................................................................................. 295 Work equipment cylinder..................................................................................................... 296 Piston valve................................................................................................................ 299 Quick drop valve............................................................................................................ 300 Pin puller switch........................................................................................................... 301 Pin puller solenoid valve................................................................................................... 302 Blade control knob.......................................................................................................... 304 Pitch, dual tilt solenoid valve............................................................................................. 305 Accumulator................................................................................................................. 306 Work equipment.................................................................................................................. 313 Cylinder stay............................................................................................................... 314 Blade....................................................................................................................... 316 Ripper...................................................................................................................... 322 Cab and its attachments......................................................................................................... 325 Cab mount................................................................................................................... 326 Cab......................................................................................................................... 327 Air conditioner............................................................................................................. 329 Electrical system............................................................................................................... 331 Engine control system....................................................................................................... 332 CRI engine control system................................................................................................... 342 Monitor system.............................................................................................................. 344 Machine monitor............................................................................................................. 346 Mode selection system....................................................................................................... 362 Electrical equipment........................................................................................................ 366 Palm command control system................................................................................................. 368 Sensors..................................................................................................................... 370 KOMTRAX system.............................................................................................................. 374 20 Standard value table............................................................................................................. 0 Standard service value table.................................................................................................... 377 Standard value table for engine............................................................................................. 378 Standard value table for machine............................................................................................ 379 30 Testing and adjusting............................................................................................................ 0 Testing and adjusting, Part 1................................................................................................... 387 Tools for testing, adjusting, and troubleshooting........................................................................... 389 Testing engine speed........................................................................................................ 393 Testing intake air pressure (Boost pressure)................................................................................ 396 Testing exhaust temperature................................................................................................. 398 Testing exhaust gas color................................................................................................... 400 Adjusting valve clearance................................................................................................... 402 Testing compression pressure................................................................................................ 404 Testing blow-by pressure.................................................................................................... 406 Testing engine oil pressure................................................................................................. 407 Handling of fuel system devices............................................................................................. 408 Releasing residual pressure from fuel system................................................................................ 408 Testing fuel pressure....................................................................................................... 409 Testing fuel return rate and fuel leakage................................................................................... 410 Bleeding air from fuel circuit.............................................................................................. 414 Testing fuel circuit for leakage............................................................................................ 416 Testing and adjusting alternator belt tension............................................................................... 417 Handling controller voltage circuit......................................................................................... 418 Testing and adjusting air conditioner compressor belt....................................................................... 419 Testing fan speed........................................................................................................... 420 Testing fan circuit oil pressure............................................................................................ 421 Bleeding air from fan pump.................................................................................................. 422 Adjusting fuel control dial and decelerator pedal........................................................................... 423 Testing and adjusting, Part 2................................................................................................... 427 Testing power train oil pressure............................................................................................ 429 Adjusting transmission speed sensor......................................................................................... 438 Simple method of testing brake performance.................................................................................. 439 Adjusting brake pedal and parking brake lever............................................................................... 440 Adjusting PCCS lever console position....................................................................................... 443 Emergency escape method when power train has trouble........................................................................ 444 Adjusting clearance of idler................................................................................................ 447 Inspecting wear of sprocket................................................................................................. 448 Testing and adjusting track shoe tension.................................................................................... 449 Testing and adjusting work equipment oil pressure........................................................................... 450 Testing control circuit main pressure....................................................................................... 454 Testing PPC valve output pressure........................................................................................... 455 Adjusting play of PPC valve................................................................................................. 457 Testing outlet pressure of ripper pin puller solenoid valve................................................................. 460 Testing parts which cause hydraulic drift of blade and ripper............................................................... 461 Testing internal leakage of work equipment cylinder......................................................................... 462 Releasing residual pressure from work equipment cylinder.................................................................... 463 Bleeding air from work equipment cylinder................................................................................... 463 Adjusting ripper lever position............................................................................................. 464 Adjusting work equipment lock lever......................................................................................... 465 Adjusting blade............................................................................................................. 466 Testing and adjusting operator's cab........................................................................................ 470 Testing and adjusting, Part 3................................................................................................... 473 Special functions of machine monitor (EMMS)................................................................................. 474 Testing and adjusting, Part 4................................................................................................... 525 Adjustment method when controller has been replaced......................................................................... 526 Method of starting use of KOMTRAX terminal.................................................................................. 528 Indication by KOMTRAX terminal lamps........................................................................................ 531 Preparation work for troubleshooting for electric system.................................................................... 534 Handling of optional devices................................................................................................ 537 Pm Clinic service........................................................................................................... 538 40 Troubleshooting.................................................................................................................. 0 Failure code table and fuse locations........................................................................................... 549 Failure codes table......................................................................................................... 550 Fuse locations.............................................................................................................. 558 General information on troubleshooting.......................................................................................... 567 Points to remember when troubleshooting..................................................................................... 568 Sequence of events in troubleshooting....................................................................................... 569 Check before troubleshooting................................................................................................ 570 Classification and procedures for troubleshooting........................................................................... 571 Contents of troubleshooting table........................................................................................... 574 Connection table for connector pin numbers.................................................................................. 576 T- branch box and T- branch adapter table................................................................................... 612 Troubleshooting by failure and error codes, Part 1.............................................................................. 617 Failure code [1500L0] Transmission clutch dual engagement................................................................... 619 Failure code [15SAL1] Forward clutch oil pressure 1......................................................................... 620 Failure code [15SALH] Forward clutch oil pressure 2......................................................................... 622 Failure code [15SBL1] Reverse clutch oil pressure 1......................................................................... 624 Failure code [15SBLH] Reverse clutch oil pressure 2......................................................................... 626 Failure code [15SEL1] 1st clutch oil pressure 1............................................................................. 628 Failure code [15SELH] 1st clutch oil pressure 2............................................................................. 629 Failure code [15SFL1] 2nd clutch oil pressure 1............................................................................. 630 Failure code [15SFLH] 2nd clutch oil pressure 2............................................................................. 631 Failure code [15SGL1] 3rd clutch oil pressure 1............................................................................. 632 Failure code [15SGLH] 3rd clutch oil pressure 2............................................................................. 633 Failure code [2201L1] Right steering clutch oil pressure 1.................................................................. 634 Failure code [2201LH] Right steering clutch oil pressure 2.................................................................. 636 Failure code [2202L1] Left steering clutch oil pressure 1................................................................... 638 Failure code [2202LH] Left steering clutch oil pressure 2................................................................... 640 Failure code [2300NR] Brake thermal load.................................................................................... 642 Failure code [2301L1] Right steering brake oil pressure 1................................................................... 644 Failure code [2301LH] Right steering brake oil pressure 2................................................................... 646 Failure code [2301NR] Right steering brake thermal load..................................................................... 648 Failure code [2302L1] Left steering brake oil pressure 1.................................................................... 650 Failure code [2302LH] Left steering brake oil pressure 2.................................................................... 652 Failure code [2302NR] Left steering brake thermal load...................................................................... 654 Failure code [6001ZK] Failure code for design............................................................................... 654 Failure code [A000NS] Engine overheat....................................................................................... 655 Failure code [AA10NX] Air cleaner clogging.................................................................................. 656 Failure code [AB00MA] Battery charge abnormal............................................................................... 658 Failure code [B@BAZG] Eng oil press low..................................................................................... 660 Failure code [B@BAZK] Eng oil level low..................................................................................... 661 Failure code [B@BCNS] Eng coolant overheat.................................................................................. 662 Failure code [B@BCZK] Radiator coolant level low............................................................................ 662 Failure code [B@BEBF] Water gets mixed with fuel............................................................................ 663 Failure code [B@BFZK] Fuel level abnormal reduction......................................................................... 663 Failure code [B@CENS] Torque converter oil overheat......................................................................... 664 Failure code [B@CHZG] HSS charge oil pressure reduction..................................................................... 665 Failure code [B@CHZK] Power train oil level reduction....................................................................... 665 Failure code [B@GAZK] Battery electrolyte level reduction................................................................... 666 Failure code [B@HANS] Hyd oil overheat...................................................................................... 666 Failure code [B@HAZK] Hydraulic oil level reduction......................................................................... 667 Troubleshooting by failure and error codes, Part 2.............................................................................. 669 Failure code [CA111] EMC critical internal failure.......................................................................... 672 Failure code [CA115] Eng Ne and Bkup speed sens error....................................................................... 674 Failure code [CA122] Chg air (boost) press sensor high error................................................................ 676 Failure code [CA123] Chg air (boost) press sensor low error................................................................. 678 Failure code [CA131] Throttle sensor high error............................................................................. 680 Failure code [CA132] Throttle sensor low error.............................................................................. 682 Failure code [CA135] End oil press sensor high error........................................................................ 684 Failure code [CA141] Eng oil press sensor low error......................................................................... 686 Failure code [CA144] Coolant temp sens high error........................................................................... 688 Failure code [CA145] Coolant temp sens low error............................................................................ 690 Failure code [CA153] Chg air (boost) temp sensor high error................................................................. 692 Failure code [CA154] Chg air (boost) temp sensor low error.................................................................. 694 Failure code [CA187] Sens supply 2 volt low error........................................................................... 694 Failure code [CA221] Ambient press sens high error.......................................................................... 696 Failure code [CA222] Ambient press sens low error........................................................................... 698 Failure code [CA227] Sens supply 2 volt high error.......................................................................... 700 Failure code [CA234] Eng overspeed.......................................................................................... 702 Failure code [CA238] Ne speed sens supply volt error........................................................................ 704 Failure code [CA263] Fuel temp sensor high error............................................................................ 706 Failure code [CA265] Fuel temp sensor low error............................................................................. 708 Failure code [CA271] PCV1 short error....................................................................................... 709 Failure code [CA272] PCV1 open error........................................................................................ 710 Failure code [CA273] PCV2 short error....................................................................................... 711 Failure code [CA274] PCV2 open error........................................................................................ 712 Failure code [CA322] Inj #1 open/short error................................................................................ 713 Failure code [CA323] Inj #5 open/short error................................................................................ 714 Failure code [CA324] Inj #3 open/short error................................................................................ 715 Failure code [CA325] Inj #6 open/short error................................................................................ 716 Failure code [CA331] Inj #2 open/short error................................................................................ 717 Failure code [CA332] Inj #4 open/short error................................................................................ 718 Failure code [CA342] Calibration code incompatibility....................................................................... 719 Failure code [CA351] Injectors drive circuit error.......................................................................... 720 Failure code [CA352] Sens supply 1 volt low error........................................................................... 722 Failure code [CA386] Sens supply 1 volt high error.......................................................................... 724 Failure code [CA441] Battery voltage low error.............................................................................. 726 Failure code [CA442] Battery voltage high error............................................................................. 726 Failure code [CA449] Rail press very high error............................................................................. 727 Failure code [CA451] Rail press sensor high error........................................................................... 728 Failure code [CA452] Rail press sensor low error............................................................................ 730 Failure code [CA553] Rail press high error.................................................................................. 730 Failure code [CA554] Rail press sensor in range error....................................................................... 731 Failure code [CA559] No-pressure feed by supply pump 1...................................................................... 732 Failure code [CA689] Eng Ne speed sensor error.............................................................................. 736 Troubleshooting by failure and error codes, Part 3.............................................................................. 739 Failure code [CA731] Eng Bkup speed sens phase error........................................................................ 741 Failure code [CA757] All continuous data lost error......................................................................... 741 Failure code [CA778] Eng Bkup speed sensor error............................................................................ 742 Failure code [CA1633] KOMNET datalink timeout error......................................................................... 744 Failure code [CA2185] Throt sens sup volt high error........................................................................ 746 Failure code [CA2186] Throt sens sup volt low error......................................................................... 748 Failure code [CA2249] No-pressure feed by supply pump 2..................................................................... 748 Failure code [CA2555] Intake air heater relay open error.................................................................... 749 Failure code [CA2556] Intake air heater relay short error................................................................... 750 Failure code [D110KA] Battery relay holding disconnection................................................................... 752 Failure code [D110KB] Battery relay drive short circuit..................................................................... 754 Failure code [D130KA] Neutral safety relay disconnection.................................................................... 756 Failure code [D130KB] Neutral safety relay short circuit.................................................................... 758 Failure code [D161KA] Back-up alarm relay disconnection..................................................................... 760 Failure code [D161KB] Back-up alarm relay short circuit..................................................................... 762 Failure code [D190KA] Engine controller ACC signal cut relay................................................................ 764 Failure code [D190KB] Engine controller ACC signal cut relay short.......................................................... 766 Failure code [D811KR] KOMTRAX controller CAN defective communication........................................................ 768 Failure code [DAFRKR] Machine monitor CAN communication defective communication............................................. 770 Troubleshooting by failure and error codes, Part 4.............................................................................. 773 Failure code [DAQ0KT] Transmission controller internal abnormality.......................................................... 775 Failure code [DAQ1KK] Transmission controller main source voltage reduction................................................. 776 Failure code [DAQ2KK] Transmission controller load voltage reduction........................................................ 778 Failure code [DAQ5KK] Transmission controller sensor 5 V power source (1) power supply source voltage reduction............. 780 Failure code [DAQ6KK] Transmission controller sensor 24 V power supply source voltage reduction............................. 782 Failure code [DAQ7KK] Transmission controller sensor 5 V power supply source (2) power source voltage reduction............. 783 Failure code [DAQ9KQ] Transmission controller type collation (Type select signal inconsistency)............................. 784 Failure code [DAQRKR] Transmission controller CAN defective communication (Abnormality in objective component system)....... 786 Failure code [DAQSKR] Transmission controller S-NET defective communication (Abnormality in objective component system)..... 788 Failure code [DB2RKR] Engine controller CAN defective communication......................................................... 790 Failure code [DB30KT] Steering controller abnormality in controller......................................................... 792 Failure code [DB31KK] Steering controller main power supply source voltage reduction........................................ 794 Failure code [DB32KK] Load power source of steering controller power source voltage drop.................................... 796 Failure code [DB35KK] Steering controller sensor 5 V power source (1) power source voltage drop............................. 798 Failure code [DB36KK] Steering controller sensor 24 V power supply source voltage reduction................................. 800 Failure code [DB37KK] Steering controller sensor 5 V power source (2) power source voltage drop............................. 802 Failure code [DB39KQ] Steering controller type collation (Type select signal inconsistency)................................. 804 Failure code [DB3RKR] Steering controller CAN defective communication (Abnormality in objective component system)........... 806 Failure code [DB3SKR] Steering controller S-NET defective communication (Abnormality in objective component system)......... 808 Failure code [DD12KA] Shift up switch disconnection......................................................................... 810 Failure code [DD12KB] Shift up switch short circuit......................................................................... 812 Failure code [DD13KA] Shift down switch disconnection....................................................................... 814 Failure code [DD13KB] Shift down switch short circuit....................................................................... 816 Failure code [DD14KA] Parking brake lever switch disconnection.............................................................. 818 Failure code [DD14KB] Parking brake lever switch short circuit.............................................................. 820 Failure code [DDB9L4] Reverse switch disagreement........................................................................... 822 Failure code [DDK3L4] Forward switch disagreement........................................................................... 823 Failure code [DDK5KA] Gearshift switch disconnection........................................................................ 824 Failure code [DDK5KB] Gearshift switch short circuit........................................................................ 825 Failure code [DDN7KA] Blade pitch switch disconnection...................................................................... 826 Failure code [DDN7KB] Blade pitch switch short circuit...................................................................... 828 Failure code [DDN9KA] Blade tilt switch disconnection....................................................................... 830 Failure code [DDN9KB] Blade tilt switch short circuit....................................................................... 832 Failure code [DDNBLD] Ripper lift raise oil pressure switch is kept ON for long time........................................ 834 Failure code [DDNCLD] Ripper lift lower oil pressure switch is kept ON for long time........................................ 835 Failure code [DDNDLD] Ripper lift tilt-in oil pressure switch is kept ON for long time...................................... 836 Failure code [DDQ2KA] Parking brake lever switch disconnection.............................................................. 838 Failure code [DDQ2KB] Parking brake lever switch short circuit.............................................................. 840 Failure code [DDQ2L4] Parking brake lever switch disagreement............................................................... 842 Failure code [DDT5KA] Neutral switch disconnection.......................................................................... 843 Failure code [DDT5KB] Neutral switch short circuit.......................................................................... 844 Failure code [DDT5KQ] Lever specification selection (Model selection signal disagreement)................................... 845 Failure code [DGS1KX] Hydraulic oil temperature sensor input signal is out of normal range.................................. 846 Troubleshooting by failure and error codes, Part 5.............................................................................. 849 Failure code [DGT1KA] Power train oil temp sensor disconnection............................................................. 852 Failure code [DGT1KX] Power train oil temp sensor out of input signal range................................................. 854 Failure code [DH21KB] Work equipment pump oil pressure sensor short circuit................................................. 856 Failure code [DH22KA] Work equipment pump oil pressure sensor disconnection................................................. 858 Failure code [DH22KB] Work equipment pump oil pressure sensor short circuit................................................. 860 Failure code [DK10KA] Fuel control dial disconnection....................................................................... 862 Failure code [DK10KB] Fuel control dial short circuit....................................................................... 864 Failure code [DK30KA] Steering potentiometer (1) disconnection.............................................................. 866 Failure code [DK30KB] Steering potentiometer (1) short circuit.............................................................. 868 Failure code [DK30KX] Steering potentiometer (1) out of input signal range.................................................. 870 Failure code [DK30KZ] Steering potentiometer (1) disconnection or short circuit............................................. 871 Failure code [DK30L8] Steering potentiometer (1) analog signals do not agree................................................ 872 Failure code [DK31KA] Steering potentiometer (2) disconnection.............................................................. 874 Failure code [DK31KB] Steering potentiometer (2) short circuit.............................................................. 876 Failure code [DK40KA] Brake potentiometer disconnection..................................................................... 878 Failure code [DK40KB] Brake potentiometer short circuit..................................................................... 880 Failure code [DK55KX] Directional potentiometer out of input signal range................................................... 882 Failure code [DK55KZ] Directional potentiometer disconnection or short circuit.............................................. 883 Failure code [DK55L8] Directional potentiometer analog signals do not agree................................................. 884 Failure code [DK56KA] F-R potentiometer (1) disconnection................................................................... 886 Failure code [DK56KB] F-R potentiometer (1) short circuit................................................................... 888 Failure code [DK57KA] F-R potentiometer (2) disconnection................................................................... 890 Failure code [DK57KB] F-R potentiometer (2) short circuit................................................................... 892 Failure code [DK60KA] Acceleration sensor disconnection..................................................................... 894 Failure code [DK60KB] Acceleration sensor short circuit..................................................................... 896 Failure code [DKH1KA] Pitch angle sensor disconnection...................................................................... 898 Failure code [DKH1KB] Pitch angle sensor short circuit...................................................................... 900 Failure code [DKH1KX] Pitch angle sensor out of input signal range.......................................................... 902 Failure code [DLT3KA] Transmission out-speed sensor disconnection........................................................... 904 Failure code [DLT3KB] Transmission out-speed sensor abnormal................................................................ 906 Failure code [DV00KB] Caution buzzer short circuit.......................................................................... 907 Failure code [DW59KA] Blade dual selector solenoid disconnection............................................................ 908 Failure code [DW59KB] Blade dual selector solenoid short circuit............................................................ 910 Failure code [DW59KY] Blade dual selector solenoid hot short................................................................ 912 Failure code [DW5AKA] Blade pitch selector solenoid disconnection........................................................... 913 Failure code [DW5AKB] Blade pitch selector solenoid short circuit........................................................... 914 Failure code [DW5AKY] Blade pitch selection solenoid hot short circuit...................................................... 916 Troubleshooting by failure and error codes, Part 6.............................................................................. 919 Failure code [DW7BKA] Fan rev EPC disconnection............................................................................. 921 Failure code [DW7BKB] Fan rev EPC short circuit............................................................................. 922 Failure code [DW7BKY] Fan reverse solenoid hot short circuit................................................................ 923 Failure code [DWN3KA] Sudden stop prevention solenoid disconnection......................................................... 924 Failure code [DWN3KB] Sudden stop prevention solenoid short circuit......................................................... 926 Failure code [DWN3KY] Sudden stop prevention solenoid hot short circuit..................................................... 928 Failure code [DWN5KA] Fan pump solenoid disconnection....................................................................... 930 Failure code [DWN5KB] Fan pump solenoid short circuit....................................................................... 932 Failure code [DWN5KY] Fan pump solenoid hot short circuit................................................................... 934 Failure code [DXH4KA] 1st clutch ECMV disconnection......................................................................... 936 Failure code [DXH4KB] 1st clutch ECMV short circuit......................................................................... 938 Failure code [DXH4KY] 1st clutch ECMV hot short circuit..................................................................... 940 Failure code [DXH5KA] 2nd clutch ECMV disconnection......................................................................... 942 Failure code [DXH5KB] 2nd clutch ECMV short circuit......................................................................... 944 Failure code [DXH5KY] 2nd clutch ECMV hot short circuit..................................................................... 946 Failure code [DXH6KA] 3rd clutch ECMV disconnection......................................................................... 948 Failure code [DXH6KB] 3rd clutch ECMV short circuit......................................................................... 950 Failure code [DXH6KY] 3rd clutch ECMV hot short circuit..................................................................... 952 Failure code [DXH7KA] Reverse clutch ECMV disconnection..................................................................... 954 Failure code [DXH7KB] Reverse clutch ECMV short circuit..................................................................... 956 Failure code [DXH7KY] R clutch ECMV hot short circuit ...................................................................... 958 Failure code [DXH8KA] Forward clutch ECMV disconnection..................................................................... 960 Failure code [DXH8KB] Forward clutch ECMV short circuit..................................................................... 962 Failure code [DXH8KY] F clutch ECMV hot short circuit ...................................................................... 964 Failure code [DXH9KA] Right steering clutch ECMV disconnection.............................................................. 966 Failure code [DXH9KB] Right steering clutch ECMV short circuit.............................................................. 968 Failure code [DXH9KY] Right steering clutch ECMV hot short.................................................................. 970 Failure code [DXHAKA] Left steering clutch ECMV disconnection .............................................................. 972 Failure code [DXHAKB] Left steering clutch ECMV short circuit .............................................................. 974 Failure code [DXHAKY] Left steering clutch ECMV hot short................................................................... 976 Failure code [DXHBKA] Right brake ECMV disconnection........................................................................ 978 Failure code [DXHBKB] Right brake ECMV short circuit........................................................................ 980 Failure code [DXHBKY] Right brake ECMV hot short circuit.................................................................... 982 Failure code [DXHCKA] Left brake ECMV disconnection......................................................................... 984 Failure code [DXHCKB] Left brake ECMV short circuit......................................................................... 986 Failure code [DXHCKY] Left brake ECMV hot short circuit..................................................................... 988 Troubleshooting of electrical system (E-mode)................................................................................... 991 Information in troubleshooting table........................................................................................ 993 E-1 The engine does not start............................................................................................... 994 E-2 The preheater does not operate (Manual preheating function)............................................................. 997 E-3 The ripper pin puller cylinder does not operate.........................................................................1000 E-4 The machine monitor does not come on at all when the starting switch is turned ON.......................................1002 E-5 When the starting switch is turned ON, the machine monitor completely remains lighted and does not go out...............1004 E-6 When the starting switch is turned ON, the basic check items flash......................................................1005 E-7 While the engine is operating, any caution item flashes.................................................................1006 E-8 While the engine is operating, the emergency warning item flashes.......................................................1009 E-9 While the preheater is operating, the preheating pilot lamp does not come on............................................1014 E-10 At the selecting time of dual tilt, the dual/single tilt selector lamp does not come on (Dual tilt-mounted machine)....1016 E-11 The engine coolant temperature gauge does not indicate normally........................................................1017 E-12 Indication of the power train (torque converter) temperature gauge is abnormal.........................................1018 E-13 The hydraulic oil temperature gauge does not indicate normally.........................................................1020 E-14 Indication of the fuel gauge is abnormal...............................................................................1021 E-15 Indications of gear speed and engine speed are abnormal................................................................1022 E-16 Indication of the shift mode service meter is abnormal.................................................................1022 E-17 The switch module cannot be operated...................................................................................1023 E-18 The warning lamp does not flash or does not go out.....................................................................1024 E-19 The alarm buzzer does not sound or does not stop.......................................................................1025 E-20 Auto shift down is not possible or is not released.....................................................................1026 E-21 The alarm buzzer cannot be cancelled...................................................................................1027 E-22 The operator mode cannot be operated...................................................................................1028 E-23 The service mode cannot be operated....................................................................................1030 E-24 The back-up alarm does not sound.......................................................................................1032 E-25 The night light, the headlamp, the working lamp and the rear lamp on the panel do not come on..........................1034 E-26 The air conditioner does not operate...................................................................................1040 E-27 KOMTRAX system does not operate normally...............................................................................1046 E-28 Fan does not reverse...................................................................................................1048 E-29 Gear cannot be shifted.................................................................................................1050 E-30 Electric priming pump does not operate or does not stop automatically..................................................1052 Troubleshooting of hydraulic and mechanical system (H-mode).....................................................................1055 Information in troubleshooting table........................................................................................1057 H-1 No travel power (No drawbar pull).......................................................................................1058 H-2 Machine does not move (At 2nd or 3rd speed).............................................................................1059 H-3 Machine does not move in any speed range................................................................................1060 H-4 Machine travels only in one direction forward or in reverse.............................................................1061 H-5 When gear is shifted or travel direction is changed, large time lag is made.............................................1062 H-6 Steering is not possible................................................................................................1063 H-7 Steering is possible only on one side...................................................................................1064 H-8 Steering overrun occurs.................................................................................................1065 H-9 Brake does not work.....................................................................................................1066 H-10 Overheat of power train oil temperature................................................................................1067 H-11 All work equipment speeds are slow.....................................................................................1068 H-12 Work equipment does not move...........................................................................................1069 H-13 Blade lift speed is slow or lacks power................................................................................1070 H-14 Blade tilt speed is slow or lacks power................................................................................1071 H-15 Ripper lift speed is slow or lacks power...............................................................................1072 H-16 Ripper tilt speed is slow or lacks power...............................................................................1073 H-17 Excessive hydraulic drift of blade lift................................................................................1074 H-18 Excessive hydraulic drift of blade tilt................................................................................1075 H-19 Excessive hydraulic drift of ripper lift...............................................................................1076 H-20 Ripper pin puller cylinder does not work (Giant ripper attachment machine).............................................1077 H-21 Blade pitch does not work (Dual tilt attachment machine)...............................................................1078 H-22 Abnormal sound comes out from around work equipment pump...............................................................1079 H-23 Fan speed is abnormal (Sound and/or vibration of fan are/is abnormally large or engine overheats)......................1080 H-24 Operator’s seat isolator quakes abnormally or makes shocks (Machine with operator’s seat isolator).....................1081 Troubleshooting of engine (S-mode)..............................................................................................1083 Method of using troubleshooting chart.......................................................................................1085 S-1 Starting performance of engine is poor..................................................................................1088 S-2 Engine does not start...................................................................................................1089 S-3 Engine does not pick up smoothly........................................................................................1092 S-4 Engine stops during operation...........................................................................................1093 S-5 Engine does not rotate smoothly.........................................................................................1094 S-6 Engine lack output (or lacks power).....................................................................................1095 S-7 Exhaust gas is black (incomplete combustion)............................................................................1096 S-8 Oil consumption is excessive (or exhaust gas is blue)...................................................................1097 S-9 Oil becomes dirty quickly...............................................................................................1098 S-10 Fuel consumption is excessive..........................................................................................1099 S-11 Oil is in coolant (or coolant spurts back or coolant level goes down)..................................................1100 S-12 Oil pressure drops.....................................................................................................1101 S-13 Oil level rises (Entry of coolant or fuel).............................................................................1102 S-14 Coolant temperature becomes too high (Overheating).....................................................................1103 S-15 Abnormal noise is made.................................................................................................1104 S-16 Vibration is excessive.................................................................................................1105 S-17 Air cannot be bled from fuel circuit..................................................................................1106 50 Disassembly and assembly......................................................................................................... 0 General information on disassembly and assembly.................................................................................1109 How to read this manual.....................................................................................................1110 Coating materials list......................................................................................................1112 Special tool list...........................................................................................................1115 Sketchs of special tools....................................................................................................1123 Engine and cooling system.......................................................................................................1133 Removal and installation of fuel supply pump assembly.......................................................................1134 Removal and installation of fuel injector assembly..........................................................................1139 Removal and installation of cylinder head assembly..........................................................................1144 Removal and installation of engine front seal...............................................................................1155 Removal and installation of engine rear seal................................................................................1159 Removal and installation of engine assembly.................................................................................1163 Removal and installation of radiator assembly (including hydraulic oil cooler assembly and aftercooler assembly)............1168 Removal and installation of hydraulic oil cooler assembly...................................................................1172 Removal and installation of aftercooler assembly............................................................................1174 Removal and installation of radiator guard assembly.........................................................................1177 Removal and installation of fuel tank assembly..............................................................................1182 Removal and installation of engine hood assembly............................................................................1184 Removal and installation of fan drive assembly..............................................................................1186 Removal and installation of fan motor assembly..............................................................................1188 Power train, Part 1.............................................................................................................1191 Removal and installation of damper assembly.................................................................................1192 Disassembly and assembly of damper assembly.................................................................................1195 Removal and installation of power train unit assembly.......................................................................1200 Disconnection and connection of power train unit assembly...................................................................1204 Disassembly and assembly of PTO assembly....................................................................................1214 Disassembly and assembly of torque converter assembly.......................................................................1221 Disassembly and assembly of torqflow transmission assembly..................................................................1226 Power train, Part 2.............................................................................................................1247 Removal and installation of scavenging pump.................................................................................1248 Disassembly and assembly of steering case assembly..........................................................................1249 Removal and installation of final drive assembly............................................................................1264 Disassembly and assembly of final drive assembly............................................................................1266 Undercarriage and frame, Part 1.................................................................................................1281 Removal and installation of track frame assembly............................................................................1282 Removal and installation of recoil spring assembly..........................................................................1286 Disassembly and assembly of recoil spring assembly..........................................................................1294 Removal and installation of idler assembly..................................................................................1296 Disassembly and assembly of idler assembly..................................................................................1298 Removal and installation of track roller assembly...........................................................................1301 Disassembly and assembly of track roller assembly...........................................................................1305 Removal and installation of carrier roller assembly.........................................................................1308 Disassembly and assembly of carrier roller assembly.........................................................................1309 Removal and installation of 1st bogie assembly..............................................................................1312 Removal and installation of 2nd, 3rd and 4th bogie assembly.................................................................1324 Disassembly and assembly of bogie assembly..................................................................................1336 Undercarriage and frame, Part 2.................................................................................................1341 Expanding and installing track shoe assembly................................................................................1342 Whole disassembly and whole assembly of track shoe assembly.................................................................1345 Removal and installation of pivot shaft assembly............................................................................1367 Removal and installation of equalizer bar assembly..........................................................................1368 Disassembly and assembly of equalizer bar bushing...........................................................................1371 Hydraulic system................................................................................................................1375 Removal and installation of work equipment pump assembly....................................................................1376 Removal and installation of power train and steering lubricating oil pump assembly..........................................1378 Removal and installation of fan pump assembly...............................................................................1380 Removal and installation of control valve assembly..........................................................................1382 Disassembly and assembly of work equipment control valve assembly...........................................................1386 Disassembly and assembly of hydraulic cylinder assembly.....................................................................1387 Work equipment..................................................................................................................1395 Removal and installation of blade assembly..................................................................................1396 Disassembly and assembly of ripper assembly.................................................................................1398 Cab and its attachments.........................................................................................................1403 Removal and installation of ROPS guard......................................................................................1404 Removal and installation of operator’s cab assembly.........................................................................1405 Removal and installation of operator’s cab glass (Stuck glass)..............................................................1407 Removal and installation of air conditioner unit assembly...................................................................1416 Removal and installation of floor frame assembly............................................................................1419 Disassembly and assembly of operator's seat isolator........................................................................1424 Electrical system...............................................................................................................1427 Removal and installation of transmission controller assembly................................................................1428 Removal and installation of steering controller assembly....................................................................1429 Removal and installation of engine controller assembly......................................................................1430 Removal and installation of monitor panel assembly..........................................................................1431 90 Diagrams and drawings............................................................................................................ 0 Hydraulic circuit diagram.......................................................................................................1433 Hydraulic circuit diagram...................................................................................................1435 Power train hydraulic circuit diagram.......................................................................................1436 Electrical diagrams and drawings................................................................................................1439 Electrical circuit diagram (1/13)...........................................................................................1441 Electrical circuit diagram (2/13)...........................................................................................1442 Electrical circuit diagram (3/13)...........................................................................................1443 Electrical circuit diagram (4/13)...........................................................................................1444 Electrical circuit diagram (5/13)...........................................................................................1445 Electrical circuit diagram (6/13)...........................................................................................1446 Electrical circuit diagram (7/13)...........................................................................................1447 Electrical circuit diagram (8/13)...........................................................................................1448 Electrical circuit diagram (9/13)...........................................................................................1449 Electrical circuit diagram (10/13)..........................................................................................1450 Electrical circuit diagram (11/13)..........................................................................................1451 Electrical circuit diagram (12/13)..........................................................................................1452 Electrical circuit diagram (13/13)..........................................................................................1453 Electrical circuit diagram for inside cab...................................................................................1454 Air conditioner unit electrical circuit diagram.............................................................................1455 Connectors table and arrangement drawing....................................................................................1457
KOMATSU D275A-5R CRAWLER BULLDOZER SHOP MANUAL SEN02158-12 – PDF DOWNLOAD:
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