Komatsu D275A-2 Bulldozer (10001 and up) Service Repair Shop Manual - SEBM000207

This complete Service Repair Workshop Manual PDF Download for the D275A-2 Komatsu Bulldozer (10001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D275A-2 Bulldozer
Serial Numbers : 10001 and up


TABLE OF CONTENTS :

01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM000207
Total Pages : 744


This (OEM) Komatsu Shop Manual has detailed illustrations as well as step by step instructions, It is 100 percents complete and intact. they are specifically written for the do-it-yourself-er as well as the experienced mechanic. With step by step instruction & highly detailed exploded pictures & diagrams to show you how to complete the required job correctly & efficiently Using. Provides step-by-step instructions based on the complete dis-assembly of the machine. It is this level of detail, along with hundreds of photos and illustrations, that guide the reader through each service and repair procedure. Complete download comes in pdf format which can work under all PC based windows operating system and Mac also, All pages are printable. Using this repair manual is an inexpensive way to keep your vehicle working properly.

This service repair workshop manual PDF download 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 is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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COVER
CONTENTS
FOREWARD
FOREWARD
HOW TO BE READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DIASSEMBLING, CONNEXTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHENING TORQUE
ELECTRIC WIRE
CONVERSION TABLE
UNITS

01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
LIST OF LUBRICANT AND WATER

10 STRUCTURE AND FUNCTION
GENERAL
POWER TRAIN
POWER TRAIN UNIT
POWER TRAIN UNIT MOUNT
POWER TRAIN PIPING
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
DAMPER AND UNIVERSAL JOINT
TORQUE CONVERTER - PTO
TORQUE CONVERTER VALVE
TRANSMISSION
TRANSMISSION CONTROL
TRANSMISSION CONTROL VALVE
TRANSMISSION LUBRICATION RELIEF VALVE
SCAVENGING PUMP
OIL STRAINER
POWER TRAIN OIL FILTER AND LUBRICATION OIL FILTER
STEERING UNIT
TRANSFER, BEVEL PINION
BEVEL GEAR, STEERING CLUTCH AND STEERING BRAKE
STEERING CONTROL
STEERING CONTROL VALVE
FINAL DRIVE
MAIN FRAME
TRACK GROUP
RECOIL SPRING
SUSPENSION
HYDRAULIC PIPING
BLADE
VARIABLE MULTIPLE SHANK RIPPER
VARIABLE GIANT RIPPER
HYDRAULIC CONTROL
BLADE CONTROL
BLADE CONTROL (For dual tilt dozer)
RIPPER CONTROL
HYDRAULIC CIRCUIT SYSTEM
HYDRAULIC CIRCUIT DIAGRAM
HYDRAULIC TANK
BLADE LIFT CONTROL VALVE
BLADE TILT CONTROL AND RIPPER LOW VALVE
RIPPER HIGH VALVE
RIPPER TILT SUCTION VALVE
PISTON VALVE
QUICK DROP VALVE
CYLINDER STAY
SEMI U-DOZER
RIPPER
VARIABLE MULTIPLE SHANK RIPPER
VARIABLE GIANT RIPPER
PIN PULLER SOLENOID VALVE
ELECTRICAL CIRCUIT DIAGRAM
CHASSIS ELECTRICAL CIRCUIT DIAGRAM (1/2)
CAB ELECTRICAL CIRCUIT DIAGRAM
AIR CONDITIONER ELECTRICAL CIRCUIT DIAGRAM
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM)
APS CONTROL SYSTEM
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM
MACHINE MONITOR SYSTEM (WITH SSC SYSTEM)
MODEL SELECTION SYSTEM
ENGINE CONTROL SYSTEM
ELPC CONTROLLER
ELPC ACTUATOR
TORQUE CONVERTER LOCK-UP CONTROL SYSTEM

20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL JUDGEMENT
TABLE OF TOOLS FOR TESTING, ADJUSTING AND TROUBLESHOOTING
TESTING AND ADJUSTING BELT TENSION
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOWBY
ADJUSTING FUEL INJECTION TIMING
MEASURING EXHAUST COLOR
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE SPEED
MEASURING BOOST PRESSURE
MEASURING EXHAUST TEMPERATURE
ADJUSTMENT OF FUEL CONTROL LINKAGE
ADJUSTMENT OF FUEL CONTROL LINKAGE (WITH SSC SYSTEM)
ADJUSTMENT OF GEAR SHIFT LEVER LINKAGE
ADJUSTMENT OF STEERING CLUTCH LINKAGE
ADJUSTMENT OF BRAKE PEDAL LINKAGE
ADJUSTMENT OF WORK EQUIPMENT CONTROL LINKAGE
ADJUSTING CLEARANCE OF IDLER
MEASURING SPEED AT TORQUE CONVERTER STALL
MEASURING SPEED AT TORQUE CONVERTER STALL + HYDRAULIC PUMP RELIEF (FULL STALL)
MEASURING POWER TRAIN OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT MAIN RELIEF PRESSURE
BLEEDING AIR FROM HYDRAULIC CYLINDER
MEASURING LEAKAGE INSIDE CYLINDER
CHECKING LOCATION OF CAUSE OF HYDRAULIC DRIFT OF BLADE AND RIPPER
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE
PROCEDURE FOR TESTING SENSORS
TESTING AND ADJUSTING ELPC VALVE POTENTIOMETER (WITH SSC SYSTEM)
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
PRECAUTIONS WHEN CARRYING OUT MAINTENANCE
HANDLING CONNECTORS
CHECKS BEFORE TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING CHART
METHOD OF USING TROUBLESHOOTING CHARTS
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
CONNECTOR POSITION DRAWING
CONNECTION TABLE FOR CONNECTOR
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
TROUBLESHOOTING OF ENGINE
S-1 Starting performance is poor (Starting always takes time).
S-2 Engine does not start.
S-3 Engine does not pick up smoothly (Follow-up is poor).
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly (hunting).
S-6 Engine lacks output (no power).
S-7 Exhaust smoke is black (incomplete combustion).
S-8 Oil consumption is excessive (or exhaust smoke is blue).
S-9 Oil becomes contaminated quickly.
S-10 Fuel consumption is excessive.
S-11 Oil is in cooling water, or water spurts back, or water level goes down.
S-12 Oil pressure lamp lights up (drop in oil pressure).
S-13 Oil level rises.
S-14 Water temperature becomes too high (overheating).
S-15 Abnormal noise is made.
S-16 Vibration is excessive.
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM
TABLE OF FAILURE MODES AND CAUSES
H-1 Brakes do not work.
H-2 Machine does not turn. (Machine can travel only in a straight line.)
H-3 There is travel deviation.
H-4 Machine turns only in one direction (lever operated).
H-5 Time lag is excessive.
H-6 Machine travels only in one direction (forward or in reverse).
H-7 Machine does not move. (2nd, 3rd engine is running)
H-8 Machine does not move in any speed range.
H-9 Torque converter oil temperature is high.
H-10 Abnormal noise from around hydraulic pump.
H-11 Blade RAISE speed slow or work equipment lacks power.
H-12 Ripper lift speed slow, or lacks power.
H-13 Excessive hydraulic drift of blade
H-14 Excessive hydraulic drift of ripper
H-15 Torque converter lock-up does not work.
H-16 Pin-puller cylinder does not work.
TROUBLESHOOTING OF ELECTRICAL SYSTEM
E-1 Pin puller cylinder does not work (For giant ripper)
E-2 Preheating fuse No. 11 is blown (Serial No. : 10001-10167)
E-3 Defective operation of APS (Serial No. : 10168 and up)
a) Even when panel preheating switch is pressed, the APS pilot on the monitor panel does not light up.
b) When panel preheating switch in ON, the APS pilot on the monitor panel lights up, but it does not go out within the range of
c) Approx. 80 seconds after panel preheating switch is turned ON, APS pilot goes out, but starting performance is poor glow plug
d) The engine can be started with the APS, but when the starting motor stops, the engine stops also.
e) APS does not stop
E-3 Related electrical circuit diagram
a) APS pilot on monitor panel does not light up when preheating switch on panel is pressed
b) APS pilot on monitor panel does not go out even when more than 12 seconds has passed after lighting up
b-1. APS pilot stays lighted up (glow plug system short circuited)
b-2. APS pilot flashes (disconnection in APS water temperature sensor)
c) APS pilot on monitor panel lights up when starting switch is at START (short circuit with ground in nozzle system)
d) APS does not work (when there is no abnormality in Items a) - c) for Defective operation of APS)
d-1. Disconnection in C signal input system
d-2. Disconnection in glow plug system
d-3. Disconnection in nozzle system
e) APS does not stop even when water temperature is above 20°C (short circuit with ground in APS water temperature sensor system
E-4 Even when the light switch is turned ON, the lamps do not light up
a) Head lamp switch
b) Rear lamp switch
c) Working lamp switch
E-5 Even when the light switch is turned OFF, the lamps do not go out
a) Head lamp switch
b) Rear lamp switch
c) Working lamp switch
E-6 Panel switch does not work. - Abnormality in panel switch power source
TROUBLESHOOTING OF ELECTRICAL SYSTEM (WITH SSC SYSTEM)
Table of failure modes and causes (mode selection electronic system)
E-S1 Torque converter lock-up does not work (lock-up display lamp does not light up)
E-S2 Torque coverter lock-up display is abnormal
Lock-up display lamp does not go out
Lock-up display lamp does not go out
E-S3 Blown fuse no.8 of torque converter lock-up relay inside relay box
E-S4 Mode does not switch when economy mode is pressed (monitor panel LED is normal)
E-S5 Reverse slow is not actuated when REVERSE slow switch is pressed (monitor panel LED is normal)
E-S6 Shoe slip control is not actuated when shoe slip control switch is pressed (monitor panel LED is normal)
E-S7 Selected level does not change when rockbed selection mode switch is pressed (monitor panel LED is normal)
E-S8 Engine cannot be controlled, engine stalls, engine cannot be started
E-S9 Shoe slip is not detected when shoe slip control is ON
E-S10 Starting modulation does not work when shoe slip control is ON
E-S11 There is no up/down of drawbar pull by using ripper lever when shoe slip control is ON
E-S12 Abnormality in ripper UP, DOWN, TILT signal, REVERSE signal
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM
Table of failure modes and causes (machine monitor, mode selection switch)
M-1 No display appears on the monitor panel when the starting switch is ON
M-2 When starting switch is turned ON, monitor panel lamps all stay on and do not go out
M-3 When starting switch is ON (engine stopped), CHECK items show abnormality (Liquid levels is normal for check items before starting)
a) Abnormality in coolant level
b) Abnormality in engine oil level
M-4 Abnormality in preheating
a) Preheating monitor does not light UP
b) Preheating monitor stays lighted up
M-5 When starting switch is ON and engine is started, CAUTION items flash (When there is no abnormality in the CHECK items or engine)
a) Charge level flashes
b) Engine oil pressure flashes
c) Coolant level flashes
d) Coolant temperature flashes
e) Torque converter oil temperature flashes
f) Hydraulic oil temperature flashes
g) Electronic system abnormality flashes
M-6 Abnormality in buzzer
a) CAUTION items are flashing, but buzzer does not sound.
b) No abnormal display is given on monitor, but buzzer sound.
M-7 Abnormality in warning lamp
a) CAUTION items are flashing, but lamps do not flash
b) No abnormal display is given on monitor, but lamp lights up
M-8 Abnormality in gauge
a) Abnormality in coolant temperature gauge
b) Abnormality in torque converter oil temperature gauge
c) Abnormality in fuel level gauge
M-9 Service meter does not move after engine is started
M-10 Panel lighting for monitor panel does not light up (Liquid crystal display is normal)
M-11 After starting switch is turned ON, display LED does not light up even when mode selection switch is pressed
M-12 LED on panel is normal, but there is no output from mode selection switch module
M-13 LED on mode selection switch panel does not flash when lighting switch is ON
M-14 Defective initial setting
Initial setting cannot be made when initial set switch is ON
Initial setting is made when initial set switch is OFF
TROUBLESHOOTING OF SHOE SLIP CONTROLLER, ELPC CONTROLLER SYSTEM (G MODE)
G-1 (Abnormality in engine) is displayed
G-2 (Abnormality in acceleration sensor power source) is displayed
G-3 (Abnormality in torque converter speed sensor) is displayed
G-4 (Abnormality in engine speed sensor) is displayed
G-5 (Abnormality in acceleration economy mode selection) is displayed
G-6 (Abnormality in control mode selection) is displayed
G-7 (Abnormality in acceleration sensor) is displayed
G-8 (Abnormality in ripping mode selection) is displayed
G-9 (Abnormality in ELPC controller) is displayed
G-10 (Abnormality in sensor power source) is displayed
G-11 (Abnormality in feedback potentiometer) is displayed
G-12 (Abnormality in input potentiometer) is displayed
G-13 (Abnormality in shoe slip control command) is displayed
G-14 (Disconnection, short circuit in solenoid system) is displayed
G-15 (Abnormality in shoe slip controller) is displayed
G-16 (Abnormality in power source) is displayed

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL
INSTALLATION
ALTERNATOR
REMOVAL
INSTALLATION
ENGINE OIL COOLER
REMOVAL
INSTALLATION
TORQUE CONVERTER OIL COOLER
REMOVAL
INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
TURBOCHARGER
REMOVAL
INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
RADIATOR AND FRONT GUARD
TURNING OVER
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
RADIATOR GUARD
REMOVAL
INSTALLATION
ENGINE
REMOVAL
INSTALLATION
DAMPER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
POWER TRAIN UNIT
REMOVAL
INSTALLATION
DISCONNECTION
CONNECTION
PTO, TORQUE CONVERTER
DISCONNECTION
CONNECTION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
PTO
DISASSEMBLY
ASSEMBLY
TORQFLOW TRANSMISSION
DISASSEMBLY
ASSEMBLY
STEERING CASE
DISASSEMBLY
ASSEMBLY
STEERING CLUTCH, BRAKE
DISASSEMBLY
ASSEMBLY
TRANSFER GEAR HOUSING
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SCAVENGING PUMP
REMOVAL
INSTALLATION
POWER TRAIN PUMP
REMOVAL
INSTALLATION
FINAL DRIVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK FRAME
REMOVAL
INSTALLATION
IDLER YOKE
REMOVAL
INSTALLATION
RECOIL SPRING
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
IDLER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CARRIER ROLLER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK SHOE
REMOVAL
INSTALLATION
OVERALL DISASSEMBLY
OVERALL ASSEMBLY
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
FIELD DISASSEMBLY OF ONE LINK
FIELD ASSEMBLY OF ONE LINK
DISASSEMBLY OF MASTER LINK
ASSEMBLY OF MASTER LINK
PIVOT SHAFT TWISTING SEAL
REMOVAL
INSTALLATION
PIVOT SHAFT
REMOVAL
INSTALLATION
EQUALIZER BAR
REMOVAL
INSTALLATION
EQUALIZER BAR SIDE BUSHING
REMOVAL
INSTALLATION
SUSPENSION CUSHION
REMOVAL
INSTALLATION
SEGMENT TOOTH
REMOVAL
INSTALLATION
HYDRAULIC PUMP
REMOVAL
INSTALLATION
BLADE LIFT VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BLADE TILT, RIPPER LOW VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
RIPPER HIGH VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
BLADE LIFT CYLINDER
REMOVAL
INSTALLATION
BLADE TILT CYLINDER
REMOVAL
INSTALLATION
RIPPER LIFT CYLINDER
REMOVAL
INSTALLATION
RIPPER TILT CYLINDER
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
DISASSEMBLY
ASSEMBLY
WORK EQUIPMENT
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
RIPPER
DISASSEMBLY
ASSEMBLY

40 MAINTENANCE STANDARD
ENGINE MOUNT
POWER TRAIN MOUNT
DAMPER AND UNIVERSAL JOINT
TORQUE CONVERTER
TORQUE CONVERTER VALVE
TRANSMISSION
TRANSMISSION CONTROL VALVE
POWER TRAIN AND LUBRICATING PUMP
TRANSFER AND BEVEL PINION
BEVEL GEAR SHAFT, STEERING CLUTCH AND STEERING BRAKE
STEERING CONTROL VALVE
FINAL DRIVE
MAIN FRAME
TRACK FRAME
RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK
SUSPENSION
HYDRAULIC PUMP
BLADE LIFT CONTROL VALVE
MAIN RELIEF VALVE AND SHUTTLE VALVE
BLADE TILT CONTROL AND RIPPER LOW VALVE
RIPPER HIGH VALVE
HYDRAULIC CYLINDER
BLADE LIFT CYLINDER
BLADE TILT CYLINDER
RIPPER LIFT CYLINDER
RIPPER TILT CYLINDER
DUAL TILT CYLINDER
PIN PULLER CYLINDER
QUICK DROP VALVE
CYLINDER STAY
SEMI U-DOZER
CUTTING EDGE AND END BIT
RIPPER
VARIABLE MULTIPLE SHANK RIPPER
VARIABLE GIANT RIPPER

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