Komatsu D275AX-5 Bulldozer Shop Manual SEBM025509 PDF

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Komatsu D275AX-5 Bulldozer Shop Manual SEBM025509 – PDF DOWNLOAD

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Komatsu D275AX-5 Bulldozer Shop Manual SEBM025509 – PDF DOWNLOAD 

Language : English
Pages : 1092
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Komatsu D275AX-5 Bulldozer Shop Manual SEBM025509 – PDF DOWNLOAD 

MAIN MENU 0
COVER 1
CONTENTS 2
SAFETY 7
SAFETY NOTICE 7
FOREWORD 9
GENERAL 9
HOW TO READ THE SHOP MANUAL 10
HOISTING INSTRUCTIONS 11
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 12
COATING MATERIALS 14
STANDARD TIGHTENING TORQUE 16
ELECTRIC WIRE CODE 19
CONVERSION TABLE 20
UNITS 26
01 GENERAL 27
SPECIFICATION DRAWING 29
SPECIFICATIONS 30
WEIGHT TABLE 36
TABLE OF FUEL, COOLANT AND LUBRICANT 38
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 39
POWER TRAIN 42
OVERALL DRAWING OF POWER TRAIN UNIT 44
HYDRAULIC PIPING OF POWER TRAIN 46
DAMPER, UNIVERSAL JOINT 48
TORQUE CONVERTER, PTO 50
TORQUE CONVERTER 54
TORQUE CONVERTER VALVE 58
TORQUE CONVERTER VALVE 62
SCAVENGING PUMP 70
TRANSMISSION CONTROL 71
TRANSMISSION 72
TRANSMISSION ECMV 84
MAIN RELIEF VALVE 90
POWER TRAIN PUMP, STEERING LUBRICATION PUMP 93
LUBRICATION RELIEF VALVE 94
HSS SYSTEM 96
HSS PUMP 98
HSS MOTOR 114
PPC, HSS CHARGE FILTER 123
HSS CHARGE FILTER BYPASS 124
HSS OIL COOLER BYPASS VALVE 126
STEERING, BRAKE CONTROL 128
BEVEL GEAR SHAFT, HSS, BRAKE 131
BRAKE VALVE 144
BRAKE ECMV 145
PARKING BRAKE VALVE 151
SUDDEN BRAKE PREVENTION VALVE 152
FINAL DRIVE 153
SPROCKET 158
TRACK FRAME 160
RECOIL SPRING 162
IDLER 164
TRACK ROLLER 166
CARRIER ROLLER 168
TRACK ROLLER BOGIE 170
TRACK SHOE 172
MAIN FRAME 174
SUSPENSION 176
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 179
PPC CONTROL PIPING DIAGRAM 183
WORK EQUIPMENT CONTROL 184
WORK EQUIPMENT PUMP 186
COOLING FAN PUMP 202
COOLING FAN MOTOR 210
HYDRAULIC TANK 216
ACCUMULATOR 218
PPC LOCK VALVE 219
PPC VALVE – FOR BLADE 221
PPC VALVE – FOR RIPPER 228
HYDRAULIC CYLINDER 234
PISTION VALVE 237
QUICK DROP VALVE 238
PIN PULLER SWITCH 239
PIN PULLER SOLENOID VALVE 240
BLADE CONTROL KNOB 242
PITCH, DUAL TILT SOLENOID VALVE 243
CONTROL VALVE 245
DUAL TILT SPECIFICATION 249
OPERATION OF CONTROL VALVE 253
SELF-REDUCING PRESSURE VALVE 270
CYLINDER STAY 277
BLADE 279
RIPPER EQUIPMENT 285
CAB MOUNT 287
CAB 288
AIR CONDITIONER 290
ENGINE CONTROL 291
ENGINE CONTROL SYSTGEM 292
DECELERATION PTENTIOMETER 293
CRI ENGINE CONTROL SYSTEM 295
MONITOR SYSTEM 297
MONITOR PANEL 299
SENSORS 303
MODE SELECTION SYSTEM 307
SENSORS 310
ELECTRICAL EQUIPMENT 313
PALM COMMAND CONTROL SYSTEM 316
20 TESTING AND ADJUSTING 318
STANDARD VALUE TABLES 319
STANDARD VALUE TABLE FOR ENGINE 319
STANDARD VALUE TABLE FOR CHASSIS 320
TESTING AND ADJUSTING 326
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 328
MEASURING ENGINE SPEED 330
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 333
MEASURING EXHAUST TEMPERATURE 335
MEASURING EXHAUST GAS COLOR 336
ADJUSTING VALVE CLEARANCE 338
MEASURING COMPRESSION PRESSURE 339
MEASURING BLOW-BY PRESSURE 340
MEASURING ENGINE OIL PRESSURE 341
HANDLING OF FUEL SYSTEM DEVICES 342
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM 342
MEASURING FUEL PRESSURE 343
BLEEDING AIR FROM FUEL CIRCUIT 344
INSPECTION OF FUEL CIRCUIT FOR LEAKAGE 346
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 347
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 347
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL 348
MEASURING POWER TRAIN OIL PRESSURE 350
TESTING AND ADJUSTING HSS OIL PRESSURE 359
ADJUSTING TRANSMISSION SPEED SENSOR 364
BLEEDING AIR FROM HSS PUMP 365
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE 365
ADJUSTING BRAKE PEDAL AND PARKING BRAKE LEVER 366
ADJUSTING PCCS LEVER CONSOLE POSITIONG 369
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 370
ADJUSTING CLEARANCE OF IDLER 373
INSPECITNG WEAR OF SPROCKET 373
TESTING AND ADJUSTING TRACK SHOE TENSION 374
TESTING AND ADJUSTING WORK EQUIPMENT OIL PRESSURE 375
TESTING AND ADJUSTING CONTROL CIRCUIT MAIN PRESSURE 379
MEASURING PPC VALVE OUTPUT PRESSURE 380
ADJUSTING PLAY OF PPC VALVE 382
MEASURING OUTLET PRESSURE OF RIPPER PIN PULLER SOLENOID VALVE 383
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER 384
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER 385
RELEASING RESIDUAL PRESSURE FROM WORK EQUIPMENT CYLINDER 386
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER 386
ADJUSTING RIPPER LEVER POSITION 387
ADJUSTING SAFETY LOCK LEVER 388
MEASURING FAN MOTOR SPEED 389
MEASURING FAN CIRCUIT OIL PRESSURE 390
CHANGING ROTATION DIRECTION OF FAN MOTORB 389
BLEEDING AIR FROM FAN PUMP 392
ADJUSTING BLADE 393
TESTING AND ADJUSTING OPERATOR’S CAB 395
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 396
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER 442
ADJUSTMENT METHOD OF REPLACED CONTROLLER 442
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM 444
HANDLING OF OPTIONAL DEVICES 446
PM CLINIC SERVICE 447
UNDERCARRIAGE TROUBLESHOOTING REPORT 454
TROUBLESHOOTING 457
POINTS TO REMEMBER WHEN TROUBLESHOOTING 458
SEQUENCE OF EVENTS IN TROUBLESHOOTING 459
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 460
CHECKS BEFORE TROUBLESHOOTING 468
CLASSIFICATIONS AND PROCEDURS OF TROUBLESHOOTING 469
CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 472
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 483
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT) 485
CIRCUIT DRAWING FOR TRANSMISSION CONTROLLER SYSTEM (T CIRCUIT) 487
CIRCUIT DRAWING FOR STEERING CONTROLLER SYSTEM (S CIRCUIT) 489
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 491
TROUBLESHOOTING WHEN ERROR CODE IS DIAPLAYED (ERROR CODE) 516
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 520
TROUBLE CODE TABLE 521
ERROR CODE [1500LO] (TRANSMISSION CLUTCH: SEE THE LIST (L1)) 522
ERROR CODE [15SAL1] (FORWARD CLUTCH: SEE THE LIST (L1)) 523
ERROR CODE [15SALH] (FORWARD CLUTCH: SEE THE LIST (LH)) 524
ERROR CODE [15SBL1] (REVERSE CLUTCH: SEE THE LIST (L1)) 525
ERROR CODE [15SBLH] (REVERSE CLUTCH: SEE THE LIST (LH)) 526
ERROR CODE [15SEL1] (SPEED 1ST CLUTCH: SEE THE LIST (L1)) 527
ERROR CODE [15SELH] (SPEED 1ST CLUTCH: SEE THE LIST (LH)) 528
ERROR CODE [15SFL1] (SPEED 2ND CLUTCH: SEE THE LIST (L1)) 529
ERROR CODE [15SFLH] (SPEED 2ND CLUTCH: SEE THE LIST (LH)) 530
ERROR CODE [15SGL1] (SPEED 3RD CLUTCH: SEE THE LIST (L1)) 531
ERROR CODE [15SGLH] (SPEED 3RD CLUTCH: SEE THE LIST (LH)) 532
ERROR CODE [1800MW] (POWER TRAIN CLUTCH: SLIP (MW)) 533
ERROR CODE [2301L1] (RIGHT BRAKE: SEE THE LIST (L1)) 534
ERROR CODE [2301LH] (RIGHT BRAKE: SEE THE LIST (LH)) 535
ERROR CODE [2302L1] (LEFT BRAKE: SEE THE LIST (L1)) 536
ERROR CODE [2302LH] (LEFT BRAKE: SEE THE LIST (LH)) 537
ERROR CODE [AB00MA] (ALTERNATOR: MALFUNCTION (MA)) 538
ERROR CODE [AD00L2] (COMMON RAIL: SEE THE LIST (L2)) 538
ERROR CODE [AD00MA] (COMMON RAIL: DEFECTIVE FUNCTION (MA)) 539
ERROR CODE [AD10L3] (FUEL SUPPLY PUMP: SEE THE LIST (L3)) 539
ERROR CODE [AD10MA] (FUEL SUPPLY PUMP:l DEFECTIVE FUNCTION (MA)) 542
ERROR CODE [AD10MB] (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB)) 542
ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN WIRING (KA)) 543
ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB)) 544
ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN WIRING (KA)) 545
ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN SHORT CIRCUIT (KB)) 546
ERROR CODE [ADA1KA] (NO 1 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA)) 547
ERROR CODE [ADAZKB] (NO 1, 2, AND 3 INJECTOR SOLENOIDS: SHORT (KB)) 548
ERROR CODE [ADB1KA] (NO 2 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA)) 550
ERROR CODE [ADC1KA] (NO 3 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA)) 551
ERROR CODE [ADD1KA] (NO 4 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA)) 552
ERROR CODE [ADDZKB] (NO 4, 5, AND 6 INJECTOR SOLENOIDS: SHORT (KB)) 553
ERROR CODE [ADE1KA] (NO 5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA)) 555
ERROR CODE [ADF1KA] (NO 6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA)) 556
ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) 557
ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS)) 557
ERROR CODE [B@BCZK] (RADIATOR COOLANT: LEVEL REDUCTION (ZK)) 558
ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS)) 558
ERROR CODE [B@CHZG] (HSS CHARGE OIL: OIL PRESSURE REDUCTION (ZG)) 559
ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS)) 559
ERROR CODE [D110KA] (BATTERY RELAY: DISCONNECTION (KA)) 560
ERROR CODE [D110KB] (BATTERY RELAY: SHORT CIRCUIT (KB)) 561
ERROR CODE [D130KA] (NEUTRAL RELAY: DISCONNECION (KA)) 562
ERROR CODE [D130KB] (NEUTRAL RELAY: SHORT CIRCUIT (KB)) 564
ERROR CODE [D161KA] (BACK-UP ALARM RELAY: DISCONNECTION (KA)) 565
ERROR CODE [D161KB] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB)) 567
ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY: SHORT CIRCUIT (KB)) 569
ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 571
ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION /INPUT (KK)) 573
ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 574
ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 575
ERROR CODE [DAQ6KK] ( TRANSMISSION CONTROLLER COURCE POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 577
ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 578
ERROR CODE [DAQRKR] (TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 579
ERROR CODE [DAQSKR] (TRANSMISSION CONTROLLER NET COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 581
ERROR CODE [DA20KT] (ENGINE CONTROLLER POWER SUPPLY: ABNORMALITY IN CONTROLLER (KT)) 582
ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 584
ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 586
ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL: MALFUNCTION (MA)) 587
ERROR CODE [DB2RKR] (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 588
ERROR CODE [DB30KK] (STEERING CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 590
ERROR CODE [DB30KT] (STEERING CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 591
ERROR CODE [DB35KK] (STEERING CONTROLLER POTENTIOMETER POWERSUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 592
ERROR CODE [DB36KK] (STEERING CONTROLLER SENSOR POWER SUPPLY: SOURCE VOTAGE REDUCTION INPUT (KK)) 594
ERROR CODE [DB39KQ] (STEERING CONTROLLER TYPE COLLATION: TYPE SELECT SIGNALINCONSISTENCY (KQ)) 596
ERROR CODE [DB3RKR] (STEERING CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 597
ERROR CODE [DB3SKR] (STEERING CONTROLLER SNET COMMUNICATION: DEFECTIVE COMMUNICATION (KRF)) 599
ERROR CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB)) 600
ERROR CODE [DD12KA] (SHIFT UP SWITCH: DISCONNECTION (KA)) 601
ERROR CODE [DD12KB] (SHIFT UP SWITCH: SHORT CIRCUIT (KB)) 603
ERROR CODE [DD13KA] (SHIFT DOWN SWITCH: DISCONNECTION (KA)) 605
ERROR CODE [DD13KB] (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB)) 607
ERROR CODE [DD14KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) 609
ERROR CODE [DD14KB] (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) 611
ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6)) 613
ERROR CODE [DDN4LD] (RIPPER LIFT UP PRESSURE SWITCH: REFER TO TABLE (LD)) 615
ERROR CODE [DDN5LD] (RIPPER LIFT DOWN PRESSURE SWITCH: REFER TO TABLE (LD)) 616
ERROR CODE [DDN6LD] (RIPPER TILT IN PRESSURE SWIT 617
ERROR CODE [DDN7KA] (BLADE PITCH SWITCH: DISCONNECTION (KA)) 618
ERROR CODE [DDN7KB] (BLADE PITCH SWITCH: SHORT CIRCUIT (KB)) 620
ERROR CODE [DDN9KA] (BLADE TILT SWITCH: DISCONNECTION (KA)) 622
ERROR CODE [DDN9KB] (BLADE TILT SWITCH: SHORT CIRCUIT (KB)) 624
ERROR CODE [DDQ2KA] (PARKING LEVER SWITCH: DISCONNECTION (KA)) 626
ERROR CODE [DDQ2KB] (PARKING BRAKE LEVER SWITCH: SHORT CIRCUIT (KB)) 628
ERROR CODE [DDQ2L4] (PARKING BRAKE LEVER SWITCH: SEET TABLE (L4)) 630
ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 631
ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE): SEE TABLE (L6)) 632
ERROR CODE [DGE4KX] (GUEL TEMPRERATUE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 633
ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 634
ERROR CODE [DH21KA] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)) 635
ERROR CODE [DH21KB] (WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) 636
ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX)) 637
ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX)) 639
ERROR CODE [DHH3KA] (HSS PUMP OIL PRESSURE SENSOR A: DISCONNECTION (KA)) 641
ERROR CODE [DHH3KB] (HSS PUMP OIL PRESSURE SENSOR A: SHORT CIRCUIT (KB)) 642
ERROR CODE [DHH4KA] (HSS PUMP OIL PRESSURE SENSOR B: DISCONNECTION (KA)) 643
ERROR CODE [DHH4KB] (HSS PUMP OIL PRESSURE SENSOR B: SHORT CIRCUIT (KB)) 644
ERROR CODE [DK10KX] (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX)) 645
ERROR CODE [DK12KX] (DECELERATIONPOTENTIOMETER: INPUT IS OUT OF NORMAL RANGE (KX)) 647
ERROR CODE [DK30KA] (STEERING POTETIOMETER 1: DISCONNECTION (KA)) 649
ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) 651
ERROR CODE [DK30KX] (STEERING POTENTIOMETER1: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 652
ERROR CODE [DK30KZ] (STEERING POTENTIOMETER 1: DISCONNECTION OR SHORT CIRCUIT (KZ)) 652
ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1: SEE TABLE (L8)) 653
ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2: DISCONNECTION (KA)) 654
ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)) 656
ERROR CODE [DK40KA] (BRAKE POTENTIOMETER: DISCONNECTION(KA)) 657
ERROR CODE [DK40KB] (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) 659
ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 660
ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)) 660
ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) 661
ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA)) 662
ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)) 664
ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA)) 665
ERROR CODE [DK57KB] (FOREWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)) 667
ERROR CODE [DK60KA] (ACCELERATION SENSOR: DISCONNECTION (KA)) 668
ERROR CODE [DK60KB] (ACCELERATION SENSOR: SHORT CIRCUIT (KB)) 669
ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR: DISCONNECTION (KA))ERROR CODE 670
ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)) 671
ERROR CODE [DLE3LE] (ENGINE NE SPEED SENSOR: SEE TABLE (LE)) 672
ERROR CODE [DLF1KA] (TRANSMISSION OUTPUT SPEED SENSOR: DISCONNECTION (KA)) 674
ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR: SEE TABLE (LC)) 675
ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB)) 676
ERROR CODE [DW59KA] (BLADE DUAL SELECTOR SOLENOID: DISCONNECTION (KA)) 677
ERROR CODE [DW59KB] (BLADE DUAL SELECTOR SOLENOID: SHORT CIRCUIT (KB)) 678
ERROR CODE [DW5AKA] (BLADE PITCH SELECTOR SOLENOID: DISCONNECTION (KA)) 679
ERROR CODE [DW5AKB] (BLADE PITCH SELECTOR SOLENOID: SHORT CIRCUIT (KB)) 680
ERROR CODE [DWN1KA] (HSS PUMP SOLENOID LEFT: DISCONNECTION (KA)) 681
ERROR CODE [DWN1KB] (HSS PUMP SOLENOID LEFT: SHORT CIRCUIT (KB)) 682
ERROR CODE [DWN2KA] (HSS PUMP SOLEOIND RIGHT: DISCONNECTION (KA)) 683
ERROR CODE [DWN2KB] (HSS PUMP SOLENOID RIGHT: SHOR TCIRCUIT (KB)) 684
ERROR CODE [DWN3KA] (SUDDEN STOP PREVENTION SOLENOID: DISCONNECTION (KA)) 685
ERROR CODE [DWN3KB] (SUDDEN SOPT PREVENTION SOLENOID: SHORT CIRCUIT (KB)) 686
ERROR CODE [DWN4KA] (HSS FREE SOLENOID: DISCONNECTION (KA)) 687
ERROR CODE [DWN4KB] (HSS FREE SOLENOID: SHORT CIRCUIT (KB)) 688
ERROR CODE [DWN5KA] (FAN PUMP SOLENOID: DISCONNECTION (KA)) 689
ERROR CODE [DWN5KB] (FAN PUMP SOLENOID: SHORT CIRCUIT (KB)) 690
ERROR CODE [DXH1KA] (LOCK-UP SOLENOID: DISCONNECTION (KA)) 691
ERROR CODE [DXH1KB] (LOCK-UP SOLENOID: SHORT CIRCUIT (KB)) 692
ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA)) 693
ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) 694
ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA)) 695
ERROR CODE [DXH5KB] (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)) 696
ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA)) 697
ERROR CODE [DXH6KB] (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)) 698
ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) 699
ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB)) 700
ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECITON (KA)) 701
ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB)) 702
ERROR CODE [DXHBKA] (RIGHT BRAKE ECMV: DISCONNECTION (KA)) 703
ERROR CODE [DXHBKB] (RIGHT BRAKE ECMV: SHORT CIRCUIT (KB)) 704
ERROR CODE [DXHCKA] (LEFT BRAKE ECMV: DISCONNECTION (KA)) 705
ERROR CODE [DXHCKB] (LEFT BRAKE ECMV: SHORT CIRCUIT (KB)) 706
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 708
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 709
E-1 THE ENGINE DOES NOT START 710
E-2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) 712
E-3 THE RIPPER PIN PULLER CYLINDER DOES NOT OPERATE 714
E-4 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON 715
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITRO PANEL COMPLETELY REMAINS LIT AND DOES NOT GO OUT 716
E-6 WHEN THE STARTING SWITCH IS TURNED ON, THE BASIC CHEKC ITEMS FLASH 717
E-7 WHILE THE ENGINE IS OPERATING, AND CAUTION ITEM FLASHES 718
E-8 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES 720
E-9 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON 724
E-10 AT THE SELECTING TIME OF DUAL TILT, THE DUAL/SINGLE TILT SELECTOR LAMP DOES NOT COM ON (DUAL TILT-MOUNTED MACHINE) 726
E-11 AT THE LOCKING-UP OF THE TORQUE CONVERTER, THE TORQUE CONVERTER LOCK-UP DISPLAY LAMP DOES NOT COME ON 726
E-12 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 727
E-13 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL 728
E-14 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 729
E-15 INDICATION OF THE FUEL GAUGE IS ABNORMAL 730
E-16 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL 731
E-17 INDICATION OF THE SHIFT MODE SERVICE METER IS ABNORMAL 731
E-18 THE SWITCH MODULE CANNOT BE OPERATED 732
E-19 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT 733
E-20 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP 734
E-21 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED 735
E-22 PIVOT TURN IS NOT POSSIBLE OR IS NOT RELEASED 736
E-23 THE ALARM BUZZER CANNOT BE CANCELLED 737
E-24 THE OPERATOR MODE CONNOT BE OPERATED 738
E-25 THE SERVICE MODE CANNOT BE OPERATED 739
E-26 THE BACK-UP ALARM DOES NOT SOUND 741
E-27 THE NIGHT LIGHT, THE HEADLAMP, THE WORKING LAMP AND THE REAR LAMP ON THE PANEL DO NOT COME ON 742
E-28 THE AIR CONDITIONER DOES NOT OPERATE 746
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 752
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 753
H-1 NO TRAVEL POWER (NO DRAWBAR PULL) 754
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED) 755
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE 756
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTING FORWARD OR IN REVERSE 757
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE 758
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHT OR LEFT) 759
H-7 STEERING SPEED OR POWER IS LOW 759
H-8 BRAKE DOES NOT WORK 760
H-9 TORQUE CONVERTER DOES NOT LOCK-UP 760
H-10 OVERHEAT OF POWER TRAIN OIL TEMPERATURE 761
H-11 ABNORMAL SOUND AROUND HSS PUMP OR HSS MOTOR 762
H-12 ALL WORK EQUIPMENT SPEEDS ARE SLOW 763
H-13 WORK EQUIPMENT DOES NOT MOVE 764
H-14 BLADE LIFT SPEED IS SLOW OR LACKS POWER 764
H-15 BLADE TILT SPEED IS SLOW OR LACKS POWER 765
H-16 RIPPER LIFT SPEED IS SLOW OR LACKS POWER 765
H-17 RIPPER TILT SPEED IS SLOW OR LACKS POWER 766
H-18 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 766
H-19 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 767
H-20 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT 767
H-21 RIPPER PIN PULLER CYLINDER DOES NOT WORK (GIANT RIPPER ATTACHMENT MACHINE) 768
H-22 BLADE PITCH DOES NOT WORK (DUAL TILT ATTACHMENT MACHINE) 768
H-23 ABNORMAL SOUND COMES OUT FROM AROUND WORK EQUIPMENT PUMP 768
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 769
METHOD OF USING TROUBLESHOOTING CHARTS 770
S-1 Starting performance is poor (starting always takes time) 774
S-2 Engine does not start 775
a) Engine does not turn 775
b) Engine turns but no exhaust smoke comes out 776
c) Exhaust smoke comes out but engine does not start (Fuel is being injected) 777
S-3 Engine does not pick up smoothly (follow-up is poor) 778
S-4 Engine stops during operations 779
S-5 Engine does not rotate smoothly (hunting) 780
S-6 Engine lacks output (or lacks power) 781
S-7 Exhaust smoke is black (incomplete combustion) 782
S-8 Oil consumption is excessive (or exhaust smoke is blue) 783
S-9 Oil becomes contaminated quickly 784
S-10 Fuel consumption is excessive 785
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 786
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 787
S-13 Oil level rises (water, fuel in oil) 788
S-14 Water temperature becomes too high (overheating) 789
S-15 Abnormal noise is made 790
S-16 Vibration is excessive 791
30 DISASSEMBLY AND ASSEMBLY 792
HOW TO READ THIS MANUAL 796
Removal and Installation of Assemblies 796
Special Tools 796
Removal of Parts 796
Installation of Parts 796
Sketches of Special Tools 796
Disassembly and Assembly of Assemblies 797
Special Tools 797
Disassembly 797
Assembly 797
Sketches of Special Tools 797
PRECAUTIONS WHEN CARRYING OUT OPERATION 798
SPECIAL TOOL LIST 800
REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY 812
Special Tools 812
Removal 812
Installation 814
REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY 816
Removal 816
Installation 819
REMOVAL AND INSTALLATION OF NOZZEL TIP 822
Special Tools 822
Removal 822
Installation 823
Sketch of Special Tool 824
REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL 825
Special Tools 825
Removal 825
Installation 825
REMOVAL AND INSTALLATION OF ENGINE REAR SEAL 827
Special Tools 827
Removal 827
Installation 827
REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY 829
Special Tool 829
Removal 829
Installation 834
REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY 838
Removal 838
Installation 839
REMOVAL AND INSTALLATION OF MAIN RADIATOR ASSEMBLY 840
Removal 840
Installation 842
REMOVAL AND INSTALLATION OF SUB-RADIATOR ASSEMBLY 843
Removal 843
Installation 844
REMOVAL AND INSTALLATION OF HYDRAULIC OIL COOLER ASSEMBLY 845
Removal 845
Installation 846
REMOVAL AND INSTALLATION OF RADIATOR GUARD ASSEMBLY 847
Removal 847
Installation 849
REMOVAL AND INSTALLATION OF ENGINE 850
Special Tools 850
Removal 850
Installation 854
REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY 856
Special Tools 856
Removal 856
Installation 859
DISASSEMBLY AND ASSEMBLY OF DAMPER ASSEMBLY 860
Special Tools 860
Disassembly 861
Assembly 863
REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY 865
Removal 865
Installation 869
DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY 870
Disconnection 870
Connection 877
Connection Diagram of Centralized Oil Pressure Pick-Up Hoses 880
DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY 882
Disassembly 882
Assembly 885
DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY 889
Disassembly 889
Assembly 893
DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISISON ASSEMBLY 899
Special Tools 899
Disassembly 899
Assembly 907
DISASSEMBLY AND ASSEMBLY OF HSS CASE ASSEMBLY 918
Special Tools 918
Disassembly 918
Assembly 926
REMOVAL AND INSTALLATION OF SCAVENGING PUMP 938
Removal 938
Installation 938
REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY 939
Removal 939
Installation 940
REMOVAL AND INSTALLATION OF WORK EQUIPMENT AND HSS CHARGE PUMP ASSEMBLY 941
Removal 941
Installation 942
REMOVAL AND INSTALLATION OF FAN PUMP ASSEMBLY 943
Removal 943
Installation 944
REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY 945
Removal 945
Installation 946
REMOVAL AND INSTALLATION OF HSS MOTOR ASSEMBLY 947
Removal 947
Installation 947
REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY 948
Special Tools 948
Removal 948
Installation 949
Sketch of Special Tool 950
DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY 951
Special Tools 951
Disassembly 951
Assembly 956
REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY 964
Special Tool 964
Removal 964
Installation 967
Sketch of Special Tool 968
REMOVAL AND INSTALLATION OF IDLER ASSEMBLY 969
Removal 969
Installation 969
DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY 970
Special Tools 970
Disassembly 970
Assembly 971
Sketch of Special Tool 973
REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY 974
Special Tools 974
Removal 974
Installation 977
DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY 978
Special Tools 978
Disassembly 978
Assembly 978
REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY 980
Special Tools 980
Removal 980
Installation 981
Sketch of Special Tool 982
DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY 983
Special Tools 983
Disassembly 983
Assembly 984
Sketch of Special Tool 986
REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY 987
Removal 987
Installation 987
DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY 988
Special Tools 988
Disassembly 988
Assembly 989
Sketch of Special Tool 991
REMOVAL AND INSTALLATION OF 1ST BOGIE ASSEMBLY 992
Special Tools 992
Removal 992
Installation 994
Sketch of Special Tool 997
REMOVAL AND INSTALLATION OF 2ND, 3RD AND 4TH BOGIE ASSEMBLY 998
Special Tools 998
Removal 998
Installation 1000
Sketch of Special Tool 1004
DISASSEMBLY AND ASSEMBLY OF BOGIE ASSEMBLY 1006
Special Tools 1006
Disassembly 1006
Assmebly 1006
Sketch of Special Tool 1009
EXPANDING AND INSTALLING TRACK SHOE ASSEMBLY 1010
Check Before Expanding Track Shoe Assembly 1010
Expanding Track Shoe Asembly (Normal) 1010
Expanding Track Shoe Assembly 1011
Installation 1012
WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY 1013
Special Tools 1013
Whole Disassembly 1014
Whole Assembly 1016
Dimensions Table of Fitting Jig of Link Press 1028
Disassembly of 1 Link in the Field 1029
Assembly of 1 Link in the Field 1030
Disassembly of Master Link 1032
Assembly of Master Link 1033
REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY 1035
Special Tools 1035
Removal 1035
Installation 1035
REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY 1036
Special Tools 1036
Removal 1036
Installation 1037
Sketch of Special Tool 1039
DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR BUSHING 1040
Special Tools 1040
Disassembly 1040
Assembly 1040
REMOVAL AND INSTALLATION OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY 1042
Removal 1042
Installation 1044
DISASSEMBLY AND ASSEMBLY OF WORK EQUIPMENT CONTROL VALVE ASSEMBLY 1046
Assembly 1046
DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY 1047
Special Tools 1047
Disassembly 1047
Assembly 1050
REMOVAL AND INSTALLATION OF BLADE ASSEMBLY 1054
Removal 1054
Installation 1055
DISASSEMBLY AND ASSEMBLY OF RIPPER ASSEMBLY 1056
Disassembly 1056
Assembly 1058
REMOVAL AND INSTALLATION OF ROPS GUARD 1060
Removal 1060
Installation 1060
REMOVAL AND INSTALLATION OF OPERATOR’S CAB ASSEMBLY 1061
Removal 1061
Installation 1062
REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY 1063
Special Tools 1063
Removal 1063
Installation 1066
REMOVAL AND INSTALLATION OF TRANSMISSION CONTROLLER ASSEMBLY 1068
Removal 1068
Installation 1068
REMOVAL AND INSTALLATION OF STEERING CONTROLLER ASSEMBLY 1069
Removal 1069
Installation 1069
REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY 1070
Removal 1070
Installation 1070
REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY 1071
Removal 1071
Installation 1072
REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY 1073
Removal 1073
Installation 1073
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY (SERIAL NO 20001 – 20030) 1074
Removal 1074
Installation 1074
REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY (SERIAL NO 20031 and up) 1075
90 OTHERS 1077
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1078
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 1079
WORK EQUIPMENT HYDRAULIC CIRCUIT AND HSS CIRCUIT DIAGRAM 1081
DIAGRAM FOR ELECTRICAL CIRCUIT (1/4) 1083
DIAGRAM FOR ELECTRICAL CIRCUIT (2/4) 1085
DIAGRAM FOR ELECTRICAL CIRCUIT (3/4) 1087
DIAGRAM FOR ELECTRICAL CIRCUTI (4/4) 1089
DIAGRAM FOR ELECTRICAL CIRCUIT OF AIR CONDITIONER 1091
ELECTRCIAL CIRCUIT DIAGRAM OF INSIDE CAB 1092

DESCRIPTION:

Komatsu D275AX-5 Bulldozer Shop Manual SEBM025509 – PDF DOWNLOAD 

Machine model         Serial number
D275AX-5                  20001 and up

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.

IMAGES PREVIEW OF THE MANUAL:

S.V 22/12/24