D275A-2 up Shop Manual
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KOMRdbU
D275A-2 MACHINE
MODEL
SERIAL NUMBER
D275A-2
.
10001 and up
This shop manual area.
Please
Materials
.
D275A-2
mounts
are subject
the S6D170-1
of the engine,
@ 1996 KOMAl%U All Rights Reserved
attachments
your local Komatsu
and specifications
For details
02-96(03)02951
may contain
consult
and optional
distributor to change
and S6D170-2
see the 6D170-1
equipment
for those items without
that are not available
in your
you may require.
notice.
engine.
Series
and 6D170-2
Series
Engine
Shop
Manual.
oo-1 @
CONTENTS No. of page
01
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*..................
10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . ..-...............................
20
TESTING AND ADJUSTING
30
DISASSEMBLY AND ASSEMBLY . . . . . . . . . ..*................n......
40
MAINTENANCE
00-2 0
STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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00-2-3 @
SAFETY
SAFETY
NOTICE
SAFETY SAFETY
NOTICE
IMPORTANT
SAFETY
Proper
and
service
NOTICE
repair
is extremely
service and repair techniques are both effective designed
manual.
for the specific
injury to workers,
The cautions
take the necessary
situation
machine
operation.
and described
require the use of tools specially
is used to mark safety precautions
these symbols
should
always
Read the Operation carefully
6. Decide
are extremely and
Manual
the machine.
out any greasing
read all the precautions which
dangerous.
Maintenance
BEFORE operating
1. ,Before carrying
a place
in the
repair
correct
to keep
places.
keep the work area clean and make
sure that there is no dirt or oil on the floor.
or repairs,
given on the decals
carrying
out any operation,
wear safety shoes and helmet. loose work clothes,
Smoke only in the areas provided
for smok-
ing. Never smoke while working.
always
. Always
or clothes with buttons
wear
safety glasses when
trained,
7. Before
adding
hitting
oil or making
wear
safety
glasses
repairs are needed, experienced
when
welder
always carry
work. When
carrying
out welding
ways
welding
gloves,
wear
grind-
etc. have a out the work,
apron,
al-
hand
shield, cap and other clothes suited for welding work. out any operation
or more workers, procedure
always before
step of the operation.
with two
agree on the operstarting.
form your fellow workers
Always
in-
before starting any
Before starting
work,
REPAIR signs on the controls
in the operator’s 5. Keep all tools
or tracks
compartment.
in good condition
the correct way to use them.
and learn
repairs,
to prevent
and the
from moving. blade,
ripper,
bucket or any other work equipment
starting
to the
ground.
If this
work,
lower
is not possible,
insert
the
safety pin or use blocks to prevent the work equipment
from falling.
to lock all the control
In addition,
be sure
levers and hang warn-
ing signs on them. 9. When disassembling
carrying
hang UNDER
8. Before
any
on hard, level ground,
block the wheels machine
ing parts with a grinder, 3. If welding
FOR WORK
park the machine
parts with a hammer. . Always
PREPARATIONS
Do not wear
missing.
ating
parts. Always
the tools and parts in their Always
workshop
are fixed to the machine.
2. When
4. When
care-
safety, and
actions to deal with the situation.
PRECAUTIONS in operation
in this
be followed
arises or may possibly arise, first consider
keep tools and removed Mistakes
The
in this manual
purpose.
the symbol a
accompanying
fully. If any dangerous
GENERAL
for safe
by Komatsu
and safe. Some of these techniques
by Komatsu
To prevent
important
recommended
the
machine
with
before starting IO. Remove
or assembling, blocks,
jacks
support or stands
work.
all mud and oil from the steps or
other places used to get on and off the machine. Always
use the handrails,
ladders
steps when
getting
Never
on or off the machine.
jump
impossible
or
on or off the machine.
to use the handrails,
steps, use a stand to provide
If it is
ladders
or
safe footing.
00-3
SAFETY
SAFETY
PRECAUTIONS
DURING
19. Be sure to assemble
WORK
original 11 When or
removing
hydraulic
pressure
loosen them spurting Before
the oil filler cap, drain plug
slowly
measuring
to prevent
plugs,
the oil from
disconnecting
or removing
nents of the oil, water the pressure
when
compo-
or air circuits, completely
first
from
the
and
oil in the
the engine
circuits
is stopped,
are hot
so be careful
. When
installing
for the oil and water
carrying
out any work
to cool
before
on the oil or water
circuits.
20. When sure
installing that
ful when circuits.
high pressure
they
are
the battery. the negative
installing Also,
Always
remove
(-1 terminal
the lead from
use a hoist
aligning
fingers
caught
ample
capacity.
Install
the lifting
23. When
equipment
which
to prevent
and
the component
operate hit-
part. Do not work with
any
removing
covers which
ternal
pressure
or under
always
leave two
are under in-
pressure
from
a
bolts in position
sides. Slowly
removing
to break wiring 17. When
release the pres-
components,
or damage
be careful
the wiring.
may cause electrical removing
piping,
not
Damaged
fires.
stop the fuel or oil
from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor
Fuel or oil
can cause you to slip, or can
even start fires. 18. As a general
rule,
do not use gasoline
to
wash parts. In particular,
use only the mini-
mum
washing
parts.
00-4
measuring
hydraulic
that the measuring
not to get your
pressure,
tool is correctly
of gasoline
when
electrical
removing
tracks of track-type When
removing
rates suddenly,
sure, then slowly loosen the bolts to remove. 16. When
Be careful
in a hole.
24. Take care when
from
15. When
on opposite
careful to check
correctly.
check assem-
at the correct
part still raised by the hoist or crane.
spring,
or rotate at
bled before taking any measurements. equipment
Use a hoist or crane
ting any other
has
When
two holes, never insert your
Check that the wire rope, chains and hooks lifting
parts, always torques.
violently
be particularly
or hand.
use
parts
parts such as guards,
vibrate
fingers
are free from damage.
care-
connecting
tightening
protective
or parts which
22. When
Damaged
tubes for high pressure
or installing
use the specified
high speed,
hoses, make
installed.
or crane.
Always
is be-
so be extremely
that they are installed
first.
14. When raising heavy components,
places.
be sure
by contact
not twisted.
check that
21. When assembling installing
13. Before starting work, remove the leads from
slowly
parts with new parts.
hoses and wires,
that they will not be damaged
are correctly
not to get burned. Wait
places.
Replace any damaged
tubes are dangerous,
water
in their
ing operated.
circuit. 12. The
all parts again
with other parts when the machine
out.
remove
NOTICE
or installing
the
machines.
the track,
the track
sepa-
so never let anyone stand at
either end of the track.
GENERAL
FOREWORD
FOREWORD GENERAL This shop serviceman
and use it to full
of this manual
the contents
Make sure you understand
the
by giving
of repairs
him the correct way to perform
of the product and by showing
understanding
an accurate
repairs and make judgements.
the quality
as an aid to improve
prepared
has been
manual
effect at every opportunity.
mainly
This shop manual are further
chapters;
into the following
these
FUNCTION the structure
This section explains
of the structure,
an understanding
This
is divided
the manual
in a
performed
for operations
information
technical
into the each main group of components.
divided
AND
STRUCTURE
TESTING
the necessary
For ease of understanding,
service workshop. chapters
contains
and function
of each component.
It serves not only to give
material
but also serves as reference
for troubleshooting.
AND ADJUSTING explains
section
adjustments
to be made at completion charts correlating
Troubleshooting
This section
MAINTENANCE
and
before
after
repairs,
performing
as well
as
of the checks and repairs. in this section.
to “Causes” are also included
“Problems”
AND ASSEMBLY
DISASSEMBLY assembling
to be made
checks
explains
the order to be followed
each component,
when
removing,
installing,
disassembling
or
to be taken for these operations.
as well as precautions
STANDARD
This section gives the judgement
standards
when
inspecting
disassembled
parts.
NOTICE The
contained
specifications
time
and
with
the
without latest
any
advance
in this notice.
shop
manual
Use the
are subject
specifications
to change given
in the
at any book
date.
00-5
HOW TO READ THE SHOP MANUAL
FOREWORD
HOW TO READ THE SHOP MANUAL VOLUMES
REVISED
Shop manuals are issued as a guide to carrying out repairs, They are divided as follows:
When
Chassis volume: Issued for every machine model Engine volume: Issued for each engine series
pages.
Electrical volume: Attachments volume:
I
Each issued as one volume to cover all models
These various volumes are designed to avoid duplicating the same information. Therefore, to deal with all repairs for any model , it is necessary that chassis, engine, electrical and attachment volumes be available. DISTRIBUTION
AND
UPDATING
Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work.
EDITION
a manual
(@@@....)
MARK is revised,
is recorded
an edition
on the
bottom
mark of the
REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.
SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.
FILING METHOD 1. See the page number on the bottom of the page. File the pages in correct order. 2. Following examples show how to read the page number. Example 1 (Chassis volume):
Symbol
A
Remarks
Item
Special safety precautions are necessary when performing the work.
Safety
/1
I I
Caution
Special technical precautions or other precautions for preserving standards are necessary when performing the work.
Weight
Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc.
10 -3
*
Item number (IO. Structure and Function) Consecutive page number for each item. Example
2 (Engine volume):
12 - 5 Unit number (I. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item.
‘”
3. Additional
pages:
cated by a hyphen page number. Example:
Additional
(-1 and number
00-6
torque
&
Coat
Places to be coated with adhesives and lubricants, etc.
Oil, water
Places where oil, water or fuel must be added, and the capacity.
& b
Places
&
Drain
1 12-203
Added
w
after the
File as in the example.
1 o-4
10-4-I > 1O-4-2 IO-5
pages are indi-
pages -1:
~~~~~I~ 12-204
Places that require special attention for the tightening torque during assembly.
Tightening
m;yo”b”,
I
where
or
water
dd:“,ii”,“,“d. and
oil
quan-
FOREWORD
HOISTING
HOISTING
INSTRUCTIONS
INSTRUCTIONS
HOISTING Slinging near the edge of the hook may cause the rope to slip off the hook during hoisting, and a serious accident can result. Hooks have maximum strength at the middle portion.
Heavy parts (25 kg or more) must be lifted with a hoist, etc. In the DISASg every part weighing 25 kg or more indicated clearly with the symbol &
.
is
If a part cannot be smoothly removed from the machine by hoisting, the following checks should be made: I) Check
for removal
of all bolts fastening
the part to the relative 2) Check for existence ing interference
the
part caus-
part to be re-
moved.
WIRE ROPES I)
Use
adequate
weight
ropes
88%
79%
71%
41% SAD00479
of another
with
100%
parts.
depending
of parts to be hoisted,
on the
referring
to
3) Do not sling a heavy load with one rope alone, but sling with two or more ropes symmetrically wound onto the load. Slinging with one rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original winding position on the load, which can result in a dangerous accident.
the table below: 4)
Wire ropes (Standard “Z” or “S” twist ropes without galvanizing) Rope diameter mm 10 11.2
Allowable
load
KN
tons
9.8
1.0
13.7
1.4
12.5
15.7
1.6
14
21.6
2.2
16
27.5
2.8
be suspended.
18
35.3
3.6
KN (1000 kg) when two ropes make a 120”
20
43.1
4.4
22.4
*
T
Do not sling a heavy load with ropes forming a wide hanging angle from the hook. When hoisting a load with two or more ropes, the force subjected to each rope will increase with the hanging angles. The table below shows the variation of allowable load KN (kg) when hoisting is made with two ropes, each of which is allowed to sling up to 9.8 KN (1000 kg) vertically, at various hanging angles.
54.9
5.6
30
98.1
10.0
40
176.5
18.0
50
274.6
28.0
60
392.2
40.0
The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used.
2) Sling wire ropes from the middle of the hook.
portion
When two ropes sling a load vertically, to 19.6 KN (2000
hanging
kg) of total weight
This weight
angle.
can
becomes
On the other
ropes are subjected
up 9.8
hand, two
to an excessive
force
as large as 39.2 KN (4000 kg) if they sling a 19.6 KN (2000 kg) load at a lifting angle of 150”.
0 6
0
44
~~~~~
30 Lifting
60 mole
90 (degree)
120
150 SAD00480
00-7
COATING
FOREWORD
MATERIALS
COATING
The recommended
Category
coating
Komatsu code
materials
Part No.
prescribed
in Komatsu
790-129-9030
150 g
LT-1B
790-129-9050
20 g (x2)
Plastic container
50 g
Plastic container
09940-00030
Main applications, features
Tube
Adhesive
LT-3
790-129-9060 (Set of adhesivs and hardenginc
agent) LT-4
Loctite
646-50)
LG-1
LG-3
Adhesive :I Kg Hardening I agent: :500 g
*
Used to prevent rubber gaskets, rubber out and cork plugs from coming
*
effecan immediately Used in places requiring Used for plastics (except tive, strona adhesive. tetrafluoroethylene, polypropylene, polyethylene, rubber, metal, and non-metal. and vinyl chloride),
* *
*
to heat, chemicals Features: Resistance for and sealant purposes Used for anti-loosenina bolts and plugs. Used as adhesive or sealant for metal, glass, plastic
*
Used
. .
to heat, chemicals Features: Resistance subject to high Used at joint portions ture
*
Used as adhesive packings of power
*
to heat Features: Resistance Used as sealant for flange surfaces and bolts at used to prevent seilocations, high temperature zure Used as sealant for heat resistant gasket for high locations such as engine precombustion temperature exhaust pipe chamber,
250 g
Plastic container
79A-129-9110
50 cc
-
790-129-9010
200 g
Tube
Can
1 Kg
*
LG-4
790-129-9020
-
Tube
200 g
* * Plastic container
790-129-9080
1 Kg
09940-00011
250 g
Tube
LG-7
09920-00150
150 g
Tube
Rust prevention lubricant
LM-G
09940-00051
60 g
Can
Molybdenum Iudisulphide bricant
LM-P
09940-00040
200 g
Tube
G2-LI
SYG-350LI SYG-400LI SYG-400LI-A SYG-16OLI SYGA-IGOCNL
G2-CA
SSG2-400CA SYG2350CA SYG2-4OOCA-A SYG2-160CA SYGA-IGCNCA
Various
SYG2-400M
400 g (IOpercas
I I
Calcium grease
00-8
LG-5
cushions,
Can
790-129-9040
790-129-9070
are listed below.
Shop Manuals
Container
Q’ty
LT-1A
LT-2
Lithium grease
MATERIALS
*
* * * .
as sealant
for machined
holes
for or sealant train case, etc.
tempera-
gaskets
to water, oil Features: Resistance Used as sealant for flange surface, thread Also possible to use as sealant for flanges large clearance Used as sealant for mating surfaces of final case case, transmission Used as sealant flanges Used as sealant ples of hydraulic Features: Used as Used as Features: Used as fold, oil
for various
threads,
for tapered piping
plugs,
and
with drive
pipe joints, elbows,
nip-
to heat, cold Silicon based, resistance sealant for flange surface, thread sealant for oil pan, final drive case, etc. type Silicon based, quick hardening housing, intake manisealant for flywheel etc. housing, pan, thermostat
*
parts (to prevent for sliding Used as lubricant squeaking) of the thread Used to prevent seizure or scuffing when press fitting or shrink fitting etc. for linkage, bearings, Used as lubricant
.
General purpose
-
light load Used for normal temperature, at places in contact with water or steam
-
Used for places with heavy
* *
type
Various
Various
Various
?)
I3ellows
type
-
load
bearing
STANDARD
FOREWORD
STANDARD
TIGHTENING
TIGHTENING
STANDARD
The following
TORQUES
TORQUE
Exceptions
are given
TORQUE OF BOLTS AND
charts give the standard
of DISASSEMBLY
in section
TIGHTENING
tightening
NUTS torques
of bolts and nuts.
AND ASSEMBLY. 1 Kgm = 9.806 Nm
Thread diameter of bolt
*
Width across flats
T
SAD00482
SAD00481
Nm
mm
mm
6
IO
13.2+ 1.4
1.35f0.15
8
13
31.4f2.9
3.2kO.3
IO
17
65.7 * 6.8
6.7kO.7
12
19
112k9.8
11.5fl.O
14
22
177If: 19
18.0f2.0
16
24
279*29
28.5f3
18
27
383k39
39f4
20
30
549 k 58
56f6
22
32
745f78
24
36
927f98
27
41
30 33 36
55
2750+290
280+30
39
60
3280 + 340
335f35
76+8
1320f
140
46
1720*
190
50
2210f240
This torque table does not apply to the bolts with nonferrous metal washers are to be used, or which specified torque.
94.5f
10
135f
15
175f20 225+25
which nylon packings or other require tightening to otherwise
00-9
STANDARD
FOREWORD
TORQUE
TIGHTENING
Use these torques
BOLTS
OF SPLIT FLANGE for split flange
TIGHTENING
bolts.
Thread diameter of bolt
Width across flats
mm
mm
Nm
10
14
65.7f6.8
12
17
112f9.8
11.5+1
16
22
279k29
28.5f3
TIGHTENING
TORQUE
Use these torques
Tightening
I
torque kgm 6.7kO.7
FOR FLARED NUTS for flared
part of nut. SAD00483
Thread diameter of nut part mm
mm
T
Tightening Nm 24.5+ 4.9
torque
Mm 2.5f0.5
14
19
18
24
22
27
24
32
137.3f29.4
1453
30
36
176.5f29.4
18k3
33
41
196.1+49
20+5
36
46
245.2 f 49
25+5
294.2 f 49
30+5
42
00-10
Width across flats of nut part
55
49k 19.6
5f2
19.6
8+2
78.5f
TORQUE
ELECTRIC WIRE CODE
FOREWORD
ELECTRIC WIRE CODE In the wiring diagrams, various colors and symbols are employed to indicate the thickness of wires. This wire code table will help you understand WIRING DIAGRAMS. 5WB indicates a cable having a nominal number 5 and white coating with black stripe. Example:
CLASSIFICATION
BY THICKNESS
Applicable circuit
17.6
CLASSIFICATION
Color
230
Starting
BY COLOR AND CODE
-
-
-
Red & Blue
Yellow&White
Green
& Blue
-
CONVERSION
FOREWORD
CONVERSION METHOD details
TABLE TABLE
THE CONVERSION
OF USING
The Conversion
TABLE
Table
of the method
in this section
is provided
of using the Conversion
conversion
simple
to enable
For
of figures.
given below.
Table, see the example
EXAMPLE . 1.
Method
of using the Conversion
Table to convert from millimeters
to inches
55 mm into inches. Locate the number 50 in the vertical column at the left side, take this as @, then draw a horizontal
Convert (I)
line from @. (2) Locate the number
line
5 in the row across the top, take this as @, then draw a perpendicular
down from @. (3) Take the point where the two lines cross as @J. This point 0 from millimeters to inches. Therefore, 55 mm = 2.165 inches. 2.
gives the value when converting
Convert 550 mm into inches.
(I) The number 550 does not appear in the table, so divide by IO (move the decimal point one place to the left) to convert it to 55 mm.
(2) Carry out the same procedure as above to convert 55 mm to 2.165 inches. (3) The original value (550 mm) was divided by 10, so multiply 2.165 inches by 10 (move the decimal point one place to the right) to return to the original value. This gives 550 mm = 21.65 inches.
Millimeters
@-
00-l 2
to inches
1 mm = 0.03937
0
1
2
3
4
5
6
7
8
9
0 IO 20 30 40
0 0.394 0.787 1.181 1.575
0.039 0.433 0.827 1.220 1.614
0.079 0.472 0.866 1.260 1.654
0.118 0.512 0.906 1.299 1.693
0.157 0.551 0.945 1.339 1.732
0.197 0.591 0.984 1.378 1.772
0.236 0.630 1.024 1.417 1.811
0.276 0.669 1.063 1.457 1.850
0.315 0.709 1.102 1.496 1.890
0.354 0.748 1.142 1.536 1.929
. . .. .. . . . . . 50 60 70 80 90
.. . . . . . . .. . .1.969 2.362 2.756 3.150 3.543
. . .. . . . . . . .2.008 2.402 2.795 3.189 3.583
. . .. .. . . . EE& . .. . . . . . ..I ..2.126 . . . . .. . . . . . .2.087 .2.047 2.480 2.441 2.520 2.874 2.913 2.953 2.835 3.268 3.346 3.307 3.228 3.701 3.661 3.740 3.622
2.205 2.598 2.992 3.386 3.780
2.244 2.638 3.032 3.425 3.819
2.283 2.677 3.071 3.465 3.858
2.323 2.717 3.110 3.504 3.898
..I
in
CONVERSIONTABLE
FOREWORD
Millimeters to Inches 1 mm
= 0.03937
3
4
5
6
7
8
9
in
0
0.039
0.079
0.118
0.157
0.197
0.236
0.276
0.315
0.354
10
0.394
0.433
0.472
0.512
0.551
0.591
0.630
0.669
0.709
0.748
20
0.787
0.827
0.866
0.906
0.945
0.984
1.024
1.063
1.102
1.142
30
1.181
1.220
1.260
1.299
1.339
1.378
1.417
1.457
1.496
1.536
40
1.575
1.614
1.654
1.693
1.732
1.772
1.811
1.850
1.890
1.929
50
1.969
2.008
2.047
2.087
2.126
2.165
2.205
2.244
2.283
2.323
60
2.362
2.402
2.441
2.480
2.520
2.559
2.598
2.638
2.677
2.717
70
2.756
2.795
2.835
2.874
2.913
2.953
2.992
3.032
3.071
3.110
80
3.150
3.189
3.228
3.268
3.307
3.346
3.386
3.425
3.465
3.504
90
3.543
3.583
3.622
3.661
3.701
3.740
3.780
3.819
3.858
3.898
0
Kilogram
to Pound
1 kg = 2.2046 lb 7
8
0
1
2
3
4
0
2.20
4.41
6.61
8.82
11.02
13.23
15.43
17.64
19.84
5
6
9
\ 0 10
22.05
24.25
26.46
28.66
30.86
33.07
35.27
37.48
39.68
41.89
20
44.09
46.30
48.50
50.71
51.91
55.12
57.32
59.53
61.73
63.93
30
66.14
68.34
70.55
72.75
74.96
77.16
79.37
81.57
83.78
85.98
40
88.18
90.39
92.59
94.80
97.00
99.21
101.41
103.62
105.82
108.03
50
110.23
112.44
114.64
116.85
119.05
121.25
123.46
125.66
127.87
130.07
60
132.28
134.48
136.69
138.89
141.10
143.30
145.51
147.71
149.91
152.12
70
154.32
156.53
158.73
160.94
163.14
165.35
167.55
169.76
171.96
174.17
80
176.37
178.57
180.78
182.98
185.19
187.39
189.60
191.80
194.01
196.21
90
198.42
200.62
202.83
205.03
207.24
209.44
211.64
213.85
216.05
218.26
00-13
CONVERSIONTABLE
FOREWORD
Liter to U.S. Gallon
It = 0.2642 U.S. Gal
1
2
3
8
9
0
0.264
0.528
0.793
1.057
1.321
1.585
1.849
2.113
2.378
IO
2.642
2.906
3.170
3.434
3.698
3.963
4.227
4.491
4.755
5.019
20
5.283
5.548
5.812
6.076
6:340
6.604
6.869
7.133
7.397
7.661
30
7.925
8.189
8.454
8.718
8.982
9.246
9.510
9.774
10.039
10.303
40
10.567
10.831
11.095
11.359
11.624
11.888
12.152
12.416
12.680
12.944
50
13.209
13.473
13.737
14.001
14.265
14.529
14.795
15.058
15.322
15.586
60
15.850
16.115
16.379
16.643
16.907
17.171
17.435
17.700
17.964
18.228
70
18.492
18.756
19.020
19.285
19.549
19.813
20.077
20.341
20.605
20.870
80
21.134
21.398
21.662
21.926
22.190
22.455
22.719
22.983
23.247
23.511
90
23.775
24.040
24.304
24.568
24.832
25.096
25.361
25.625
25.889
26.153
0
0
4
5
6
7
Liter to U.K. Gallon
It = 0.21997 U.K. Gal
1
2
3
4
0
0.220
0.440
0.660
0.880
1.100
1.320
1.540
1.760
1.980
10
2.200
2.420
2.640
2.860
3.080
3.300
3.520
3.740
3.950
4.179
20
4.399
4.619
4.839
5.059
5.279
5.499
5.719
5.939
6.159
6.379
30
6.599
6.819
7.039
7.259
7.479
7.969
7.919
8.139
8.359
8.579
40
8.799
9.019
9.239
9.459
9.679
9.899
10.119
10.339
10.559
10.778
50
0.998
11.281
11.438
11.658
11.878
12.098
12.318
12.528
12.758
12.978
60
3.198
13.418
13.638
13.858
14.078
14.298
14.518
14.738
14.958
15.178
70
15.398
15.618
15.838
16.058
16.278
16.498
16.718
16.938
17.158
17.378
80
17.598
17.818
18.037
18.257
18.477
18.697
18.917
19.137
19.357
19.577
90
19.797
20.017
20.237
20.457
20.677
20.897
21.117
21.337
21.557
21.777
0
0
00-14
5
6
7
8
9
CONVERSIONTABLE
FOREWORD
kgm to ft. lb 1 kgm = 7.233 ft. lb
0
4
1
2
3
7.2
14.5
21.7
28.9
6
7
8
9
36.2
43.4
50.6
57.9
65.1
5
\\ 0
0
10
72.3
79.6
86.8
94.0
101.3
108.5
115.7
123.0
130.2
137.4
20
144.7
151.9
159.1
166.4
173.6
180.8
188.1
195.3
202.5
209.8
30
217.0
224.2
231.5
238.7
245.9
253.2
260.4
267.6
274.9
282.1
40
289.3
296.6
303.8
311.0
318.3
325.5
332.7
340.0
347.2
354.4
50
361.7
368.9
376.1
383.4
390.6
397.8
405.1
412.3
419.5
426.8
60
434.0
441.2
448.5
455.7
462.9
470.2
477.4
484.6
491.8
499.1
70
506.3
513.5
520.8
528.0
535.2
542.5
549.7
556.9
564.2
571.4
80
578.6
585.9
593.1
600.3
607.6
614.8
622.0
629.3
636.5
643.7
90
651.0
658.2
665.4
672.7
679.9
687.1
694.4
701.6
708.8
716.1
100
723.3
730.5
737.8
745.0
752.2
759.5
766.7
773.9
781.2
788.4
110
795.6
802.9
810.1
817.3
824.6
831.8
839.0
846.3
853.5
860.7
120
868.0
875.2
882.4
889.7
896.9
904.1
911.4
918.6
925.8
933.1
130
940.3
947.5
954.8
962.0
969.2
976.5
983.7
990.9
998.2
1005.4
140
1012.6
1019.9
1027.1
1034.3
1041.5
1048.8
1056.0
1063.2
1070.5
1077.7
150
1084.9
1092.2
1099.4
1106.6
1113.9
1121.1
1128.3
1135.6
1142.8
1150.0
160
1157.3
1164.5
1171.7
1179.0
1186.2
1193.4
1200.7
1207.9
1215.1
1222.4
170
1129.6
1236.8
1244.1
1251.3
1258.5
1265.8
1273.0
1280.1
1287.5
1294.7
180
1301.9
1309.2
1316.4
1323.6
1330.9
1338.1
1345.3
1352.6
1359.8
1367.0
190
1374.3
1381.5
1388.7
1396.0
1403.2
1410.4
1417.7
1424.9
1432.1
1439.4
00-l 5
CONVERSIONTABLE
FOREWORD
to lb/in*
kg/cm*
1 kg/cm*
0
\
1
2
1
3
I
4
5
= 14.2233
8
lb/id
6
7
99.6
113.8
128.0
9
14.2
28.4
42.7
56.9
71.1
85.3
142.2
156.5
170.7
184.9
199.1
213.4
227.6
241.8
256.0
270.2
20
284.5
298.7
312.9
327.1
341.4
355.6
369.8
384.0
398.3
412.5
30
426.7
440.9
455.1
469.4
483.6
497.8
512.0
526.3
540.5
554.7
40
568.9
583.2
597.4
611.6
625.8
640.1
654.3
668.5
682.7
696.9
50
711.2
725.4
739.6
753.8
768.1
782.3
796.5
810.7
825.0
839.2
60
853.4
867.6
881.8
896.1
910.3
924.5
938.7
953.0
967.2
981.4
70
995.6
0
0
10
1010
1024
1038
1053
1067
1081
1095
1109
1124
80
1138
1152
1166
1181
1195
1209
1223
1237
1252
1266
90
1280
1294
1309
1323
1337
1351
1365
1380
1394
1408
100
1422
1437
1451
1465
1479
1493
1508
1522
1536
1550
110
1565
1579
1593
1607
1621
1636
1650
1664
1678
1693
120
1707
1721
1735
1749
1764
1778
1792
1806
1821
1835
130
1849
1863
1877
1892
1906
1920
1934
1949
1963
1977
140
1991
2005
2020
2034
2048
2062
2077
2091
2105
2119
150
2134
2148
2162
2176
2190
2205
2219
2233
2247
2262
160
2276
2290
2304
2318
2333
2347
2361
2375
2389
2404
170
2418
2432
2446
2460
2475
2489
2503
2518
2532
2546
180
2560
2574
2589
2603
2617
2631
2646
2660
2674
2688
190
2702
2717
2731
2745
2759
2773
2788
2802
2816
2830
200
2845
2859
2873
2887
2901
2916
2930
2944
2958
2973
210
2987
3001
3015
3030
3044
3058
3072
3086
3101
3115
220
3129
3143
3158
3172
3186
3200
3214
3229
3243
3257
230
3271
3286
3300
3314
3328
3343
3357
3371
3385
3399
240
3414
3428
3442
3456
3470
3485
3499
3513
3527
3542
00-l 6
CONVERSION
FOREWORD
TABLE
Temperature Fahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature
reading intoa Centigradetempera-
ture reading or vice versa isto enter the accompanying table in the center or boldfacecolumn of figures. These figuresrefer to the temperature in eitherFahrenheitor Centigrade degrees. Ifitis desired to convert from Fahrenheitto Centigrade degrees, consider the center column as a table of Fahrenheit temperatures and read the corresponding Centigrade Ifitisdesired to convert from Centigrade and read the corresponding Fahrenheit
temperature in the column at the left. to Fahrenheitdegrees,considerthecenter column as a table of
temperature
Centigradevalues,
on the right. 1°C = 33.8"F
“F
“C
“F
“C
“F
“C
“F
“C
-40.4
-40
-40.0
-11.7
11
51.8
7.8
46
114.8
27.2
81
117.8
-37.2
-35
-31.0
-11.1
12
53.6
8.3
47
116.6
27.8
82
179.6
-34.4
-30
-22.0
-10.6
13
55.4
8.9
46
118.4
28.3
83
181.4
-31.7
-25
-13.0
-10.0
14
57.2
9.4
49
120.2
28.9
84
183.2
-28.9
-20
-4.0
-9.4
15
59.0
10.0
50
122.0
29.4
85
185.0
-28.3
-19
-2.2
-8.9
16
60.8
10.6
51
123.8
30.0
86
186.8
-27.8
-18
-0.4
-8.3
17
62.6
11.1
52
125.6
30.6
87
188.6
-27.2
-17
1.4
-7.8
18
64.4
11.7
53
127.4
31.1
88
190.4
-26.7
-16
3.2
-7.2
19
66.2
12.2
54
129.2
31.7
89
192.2
-26.1
-15
5.0
-6.7
20
68.0
12.8
55
131.0
32.2
90
194.0
-25.6
-14
6.8
-6.1
21
69.8
13.3
56
132.8
32.8
91
195.8
-25.0
-13
8.6
-5.6
22
71.6
13.9
57
134.6
33.3
92
197.6
-24.4
-12
10.4
-5.0
23
73.4
14.4
58
136.4
33.9
93
199.4
-23.9
-11
12.2
-4.4
24
75.2
15.0
59
138.2
34.4
94
201.2
-23.3
-10
14.0
-3.9
25
77.0
15.6
60
140.0
35.0
95
203.0
-22.8
-9
15.8
-3.3
26
78.8
16.1
61
141.8
35.6
96
204.8
-22.2
-8
17.6
-2.8
27
80.6
16.7
62
143.6
36.1
97
206.6
-21.7
-7
19.4
-2.2
28
82.4
17.2
63
145.4
36.7
98
208.4
-21.1
-6
21.2
-1.7
29
84.2
17.8
64
147.2
37.2
99
210.2
-20.6
-5
23.0
-1.1
30
86.0
18.3
65
149.0
37.8
100
212.0
-20.0
-4
24.8
-0.6
31
87.8
18.9
66
150.8
40.6
105
221.0
-19.4
-3
26.6
0
32
89.6
19.4
67
152.6
43.3
110
230.0
-18.9
-2
28.4
0.6
33
91.4
20.0
68
154.4
46.1
115
239.0
-18.3
-1
30.2
1.1
34
93.2
20.6
69
156.2
48.9
120
248.0
-17.8
0
32.0
1.7
35
95.0
21.1
70
158.0
51.7
125
257.0
-17.2
1
33.8
2.2
36
96.8
21.7
71
159.8
54.4
130
266.0
-16.7
2
35.6
2.8
37
98.6
22.2
72
161.6
57.2
135
275.0
-16.1
3
37.4
3.3
38
100.4
22.8
73
163.4
60.0
140
284.0
-15.6
4
39.2
3.9
39
102.2
23.3
74
165.2
62.7
145
293.0
-15.0
5
41.0
4.4
40
104.0
23.9
75
167.0
65.6
150
302.0
-14.4
6
42.8
5.0
41
105.8
24.4
76
168.8
68.3
155
311.0
-13.9
7
44.6
5.6
42
107.6
25.0
77
170.6
71.1
160
320.0
-13.3
8
46.4
6.1
43
109.4
25.6
78
172.4
73.9
165
329.0
-12.8
9
48.2
6.7
44
111.2
26.1
79
174.2
76.7
170
338.0
-12.2
10
50.0
7.2
45
113.0
26.7
80
176.0
79.4
175
347.0
00-l 7
01
GENERAL
............... General assembly drawing .......................... Specifications Weight table ........................... ............... List of lubricant and water
D275A-2
Ol- 2 01- 3 Ol- 8 01-10
01-l
GENERAL ASSEMBLY DRAWING SEMI U-DOZER WITH VARIABLE
MULTIPLE
RIPPER
17MF02001
01-2
D275A-2
SPECIFICATIONS
Machine
D275A-2
model
Serial numbers
10168 and up
10001 - 10167
Operating weight l
l
Bare tractor
37200
With semi U-dozer
44180
l
Semi U-dozer with variable multiple ripper
l
Semi U-dozer with variable multiple ripper
kg
48830 50000
+ with ROPS cab assembly Minimum turning radius
m
3.9
Grade ability
degree
30
Stabilitiy (Front, rear, left, right)
degree
35
1st
7
$
2nd
2
3rd
$ 1st & 2 2nd
km/h
0-
3.8
0-
6.7
O-11.8
km/h
0-
4.9
0-
8.7
0 - 14.9
cT 3rd Bare tractor
8.63 IO.881
With Semi U-dozer
10.29 (1.05)
kPa Semi U-dozer with variable multiple ripper Semi U-dozer with variable multiple ripper (kg/cm*}
11.67 {1.19}
11.37 11.16)
+ with ROPS cab assembly Bare tractor With Semi U-dozer
5445 mm
Semi U-dozer with variable multiple ripper Bare tractor
mm
mm
Track gauge
2260 mm
Show width Minimum ground clearance
3875 2880
Except exhaust pipe, operatior’s seat
Length of track on ground
2935 4300
Wtih Semi U-dozer To top of exhaust pipe
7085 9055
3450 610
mm
507
01-3 @
Machine
D275A-2
model
Serial numbers Engine
10001
x stroke
Piston displacement
horsepower
4-cycle, water-cooled, in-line vertical, direct injection type with turbocharger mm
6-170x170
6-170x170
cc
23150
23150
kW/rpm :HP/rpmI
302/l ,800 141 O/l ,800)
302/I ,800 (41 O/l ,800)
Nm/rpm cgmlrpm
Max. torque
2,079/l
2,079/l
,300 (2 12/l ,300)
,300 (2 12/l ,300)
High idling speed
rpm
2,000
2,000
Low idling speed
rpm
630
630
Min. fuel consumption Starting
ration
up
$-cycle, water-cooled, in-line vertical, direct injection type with turbocharger
Type
No. of cylinders-bore
and
S6D170-2
S6D170-1
model
Flywheel
10168
- 10167
g/kWh {glpshl
224 {I651
214 {I581
motor
24V, 7.5kw x 2
Alternator
24V, 50A
Battery
12V, 170Ah x 2 ZG
Radiator Torque
core
D type
converter
3-element,
l-stage, single phase (with lock-up clutch)
Transmission
Planetan/ gear, multiple disc clutch, hydraulically actuated, force-feed lubrication pump, forward B-speed, reverse 3-speed
Bevel gear
Spiral bevel gear, splash type lubrication
Steering
clutch
Wet type, multiple clutch disc, spring boosted, hydraulically actuated (manual type), interconnected with brake
Steering
brake
Wet type, multiple clutch disc, spring boosted, hydraulically actuated (pedal operated, manual type), interconnected with clutch Spur gear l-stage, planetary gear l-stage reduction, splash type lubrication
Final drive Suspension Carrier
Semi-rigid
roller
balancing beam type 2 (each)
Track roller
8 (each)
Track shoe type
Assembly type, single grouser
No. of shoes
39 (each)
l
l
Pitch
mm
260.35
l
Width
mm
610
01-4 @
2 ;;
Machine
model
D275A-2
Serial numbers
RPafkglcm:
Relief valve setting Hydraulic Delivery
. Blade
pump type (at engine
lift control
. Blade tilt control Ripper
high valve
Hydraulic
cylinder
l
f
Cylinder Outside
10001
- 10167
1,800 rpm)
L?/min
valve
x 2EARlOO
3-tandem spool type 2-tandem pilot spool type
type
Reciprocal, piston type
bore
130
diameter
of Piston rod
80 mm
1,420
between
Pins
2,365
Min. distance
between
Pins
945
bore
200
diameter
of Piston rod
100 mm
Piston stroke Max.
190
distance
between
Pins
1,555
Min. distance
between
Pins
1,365
Cylinder Outside
bore
200
diameter
of Piston rod
Min. distance
100 mm
Piston stroke Max. distance
+ 050)
288
Max. distance
Outside
up
Single spool type with demand spool
and ripper low valve
Piston stroke
Cylinder
and
20.6 (210) Gear type, 2 tandem
speed
10168
I
between between
465
Pins
1,565
Pins
1,100
01-5 @
‘efformance limension
Dozer equipment
Wrk.equipment o
017M02
Jin puller cylinder
cylinder
Dual tilt cylinder
Hydraulic Gpper tilt cylinder
D L¶
R
21
Machine
model
D275A-2
Serial numbers
10001
Type
- 10167
10168
I
Variable angle type, parallelogram
Weight Beam length
kg
4,490
mm
2,495
No. of shanks Ripping
angle
Ripping
depth
Max. digging
(standard)
degree
51.7 (Possible to adjust steplessly 36.9 - 61.2) P-stage selection possible
depth
mm
900
mm
955 Variable angle type, parallelogram
Type Weight Beam length
kg
3,640
mm
1,252
No. of shanks angle
Ripping
depth
Max. digging Max. lifting
type
3
Max. lifting height
Ripping
and up
type
1 (standard)
degree
52.7 (Possible to adjust steplessly 39.7 - 62.2) 3-stage selection possible
depth height
mm
1.300
mm
870
01-7 @
WEIGHT TABLE
A
This weight table is a guide for use when transporting or handling components. Machine model
D275A-2
Serial numbers
10001 and up
Engine and damper assembly l
Engine assembly
l
Damper assembly
l
Engine mounting parts
2810 2580 160 70
Radiator assembly
350
Oil cooler assembly
100
Fuel tank assembly (Full)
Unit: kg
390 (1150)
Power train unit Power train assembly
3360
Torque converter and PTO assembly
740
Transmission
assembly
890
Transmission
control valve assembly
Steering clutch and brake assembly Steering control valve assembly
35 1600 60
Final drive assembly (each side)
1940
Main frame assembly
4200
Track group assembly (each side)
4100
Track frame
1200
Idler assembly
340
Track roller assembly (single) (each)
110
Track roller assembly (double) (each)
120
Carrier roller assembly (each) Track shoe assembly (width 610 mm) Pivot shaft (each side)
70 6800 145
Equalizer bar
255
Bolster
195
Hydraulic tank assembly
350
l
Blade lift control valve assembly
56
l
Blade tilt and ripper low valve assmebly
47
01-8
D275A-2
Unit: kg Machine model Serial numbers
Semi-U dozer assembly
I
D275A-2
10001 and up 6330 2980
l
Blade
l
L.H. straight frame
780
l
R.H. straight frame
780
l
Tilt cylinder assembly
220
Variable multiple shank ripper assembly l
Shank assembly (each)
350
l
Lift cylinder assembly
205
l
Tilt cylinder assembly
185
Variable giant ripper assembly
3600
l
Shank assembly
500
l
Lift cylinder assembly
205
l
Tilt cylinder assembly
185
Radiator guard assembly (with cylinder yoke)
1700
l
Radiator guard
750
l
Blade lift cylinder assembly (each side)
210
Front guard (with grille)
330
Engine under guard
260
Power train under guard
330
Engine hood
90
L.H. fender
300
R.H. fender
320
ROPS mount assembly
500
ROPS assembly
580
Floor frame assembly
320
Cab assembly
490
Operator’s seat assembly
D275A-2
70
01-9
TABLE OF FUEL, COOLANT AND LUBRICANTS
KIND OF FLUID
RESERVOIR
AMBIENT TEMPERATURE -22
-4
Engine oil pan
Power train oil pan (Incl. torque converter, transmission and bevel gear case) Engine oil
Hydraulic tank
I
Gear oil
*I
Fuel tank
Diesel fuel
Cooling system
I
Add antifreeze
Coolant
*
ASTM: SAE: API:
l/4 of regular interval
American Society of Testing and Material Society of Automotive Engineers American Petroleum Institute
(2) When starting the engine in an atmospheric temperature of lower than O”C, be sure to use and SAEIOW-30 oil of SAEIOW, engine even though an atmospheric temSAEl5W-40 perature goes up to 10°C more or less in the day time. (3) Use API classification CD as engine oil and if API classification CC, reduce the engine oil change interval to half. (4) There is no problem if single grade oil is mixed with multigrade oil (SAEIOW-30, 15W-40), but be sure to add single grade oil that matches the temperature in the table on the left. Komatsu genuine oil which (5) We recommend has been specifically formulated and approved for use in engine and hydraulic work equipment applications.
Specified capacity: Total amount of oil including oil for components and oil in piping. Refill capacity: Amount of oil needed to refill system during normal inspection and maintenance.
01-10 @ .*-
-
ASTM D975 No. 1
NOTE: (1) When fuel sulphur content is less than 0.5 %, change oil in the oil pan every periodic maintenance hours described in this manual. Change oil according to the following table if fuel sulphur content is above 0.5 %.
Above 1 .O %
136
10 STRUCTURE AND FUNCTION
Z Z Z
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 ....................................... l Blade .................................................... l Variable multiple shank ripper .......... l Variable giant ripper.. ......................... Hydraulic control ...................................... l Blade control ....................................... l Blade control (for dual tilt dozer). ..... 0 Kipper control ..................................... Hydraulic circuit system .......................... Hydraulic circuit diagram ........................ Hydraulic tank.. .........................................
IO- 2 IO- 3 IO- 4 IO- 5 IO- 7 IO- 8 IO-IO IO-12 IO-16 IO-24 IO-29 IO-30 IO-37 IO-38 IO-39 IO-40 IO-42 IO-44 IO-46 IO-51 IO-52 IO-60 IO-63 IO-64 IO-65 IO-66 IO-69 IO-69 IO-70 10-70-I IO-71 IO-71 IO-72 IO-73 IO-74 IO-75 IO-77
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 ...................................................... l Variable multiple shank ripper ........ l Variable giant ripper.. ....................... Pin-puller solenoid valve ....................... Electrical circuit diagram ....................... l Chassis electrical circuit diagram.. .. l Cab electrical circuit diagram .......... l Air conditioner electrical circuit diagram ............... EVMS (Electrical vehicle monitoring system) ... APS control system ............................... Torque converter lock-up control system ......................................
IO- 78 IO- 82 IO- 84 IO- 86 IO-104 IO-105 IO-106 IO-108 10-l 10 IO-I IO IO-I 12 IO-I 12-2 10-l 14 IO-I 14 10-118-4 10-l 18-6 10-l 19 IO-132 IO-133
10-l @
GENERAL
1. Engine (S6D170) 2. Damper 3. Universal joint 4. Torque converter 5. TORQFLOW transmission
The power produced by diesel engine (1) goes from the engine flywheel to torque converter (4) through damper (2) and universal joint (3). The torque converter (4) transmits the power to transmission (5) by converting the mechanical energy - fluid energy mechanical energy. The transmission (5), with a planetary gear mechanism and a hydraulic control unit combined, allows an easy selection of three forward speeds and three reverse speeds. Through the drive shaft, the power is transmitted from transmission (5) to transfer drive gear (6) on the rear of the machine body. The transfer gears reduce the speed and, then, the power is transmitted to bevel pinion. Bevel pinion and bevel gear direct the power to the right and left, and the power is transmitted to the left and right steering clutches (7) and final drives (9).
1 o-2
6. 7. 8. 9. 10. 11.
Transfer Steering clutch Steering brake Final drive Sprocket Track
F19702001
The steering clutch connects and disconnects the power from the bevel gear shaft to final drive (9). SO that the traveling direction of the machine is controlled (steering). For example, when the R.H. steering lever is pulled, the steering control valve linked to the lever is operated, the power is disconnected, and the machine turns to the right. Steering brake (8) is installed between steering clutch (7) and final drive (9). It is the same type as the steering clutch. Steering brake (8) not only stops the machine, but also controls the turning radius of the machine. Final drive reduces the revolution speed by spur gear single reduction and planetary gear system, and the revolution speed is transmitted to sprocket (10). Sprocket (10) drives track (11).
D275A-2
POWER TRAIN
17 M F02002A
1. 2. 3. 4. 5.
Engine (S6D170) Damper Universal joint Torque converter Transmission
6. 7. 8. 9. 10.
Transfer Steering clutch Steering brake Final drive Sprocket
11. 12. 13. 14. 15.
Track shoe PTO Power train pump (BALI 00 + 140) Scavenging pump (BAR63 + 200) Hydraulic pump (SAR(3)lOO + (2)50)
10-3 0
POWER TRAIN UNIT
I4 D275A-2 10061 and up
8
SI
A 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
PTO Torque converter Torque converter valve Transmission control valve Transmission Steering clutch and brake Steering control valve Power train pump Power train oil filter Power train oil strainer Scavenging pump Power train oil tank
OUTLINE 0 The power train unit can be broadly divided into the torque converter and transmission unit and the steering unit. Therefore, after removing the power train as a unit, it can be disassembled into the torque converter and transmission unit and the steering unit. The steering unit consists of the transfer, bevel gear shaft, steering clutch, and steering brake. 17MF02003B
POWER TRAIN UNIT MOUNT
6
7
8
9 10 11
A-A 17MF02004
1. 2. 3. 4. 5. 6.
D275A-2
Main frame PTO Torque converter Transmission Steering clutch and brake Cage
7. 8. 9. 10. 11.
Clamp Seal Cover Coupling Cap
1o-5
Oil cooler Power train lubrication oil filter Power train oil filter Torque converter valve Transmission control valve Steering control valve Oil tank Power train oil strainer Power train pump Scavenging pump
D275A-2
1 o-7
?
setpressure 2.7 kg/cm2
! r
!t
pressure i--J Se 1!7I f 1 kg/cm2
Cracking pressw 1.4 kg/cm2
:racking ,VZS”E
ir i
1:
.4 kg/cm*
; 46 F17M02001A
Plug for transmission main relief pressure Plug for torque converter relief pressure Plug for torque converter regulator pressure Plug for torque converter stator clutch modulating pressure Plug for torque converter lock-up pressure Plug for transmission reducing pressure Plug for R.H. steering clutch pressure Plug for R.H. brake pressure Plug for L.H. brake pressure Plug for L.H. steering clutch pressure
1 O-8 0
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43. 44. 45. 46.
Oil tank Power train oil strainer Power train pump (BALI401 Power train lubrication pump (BALIOO) Power train oil filter Main relief valve Modulating valve Quick return valve Reducing valve Transmission F-R valve Transmission speed valve Reverse clutch Forward clutch 3rd speed clutch 2nd speed clutch 1st speed clutch Power train lubrication oil filter PTO lubrication Transmission lubrication valve Transmission lubrication Transmission case Torque converter relief valve Torque converter case Torque converter Torque converter lock-up modulating valve Torque converter lock-up clutch Stator clutch modulating valve Stator clutch Torque converter lock-up selector valve Torque converter lock-up solenoid valve Stator and clutch lubrication R.H. steering clutch valve R.H. brake valve L.H. brake valve L.H. steering clutch valve Pin puller solenoid valve Pin puller cylinder Steering clutch and brake lubrication R.H. Steering clutch R.H. Brake L.H. Brake L.H. Steering clutch Steering case Scavenging pump (BAR63 + 200) Oil cooler Oil filler
8
E 6
DAMPER AND UNIVERSAL JOINT
r-7
17MF02007
10-10
D275A-2
OUTLINE The damper acts as a cushion to prevent the vibration of the engine from being transmitted directly to the torque converter and transmission. The power from the engine is transmitted to damper outer body (1) through flywheel (9). The power is absorbed the engine vibration by rubber coupling (7), and is transmitted to shaft (8) and universal joint (4), and then is transmitted to the torque converter. As the damper uses rubber, it absorbs the vibration by the vibration-reducing effect of rubber, and the twist by the friction-reducing effect of the deformation of the rubber. The number of part is fewer than the friction plate type damper.
I. 2. 3. 4. 5. 6. 7. 8. 9.
Outer body Oil level gauge Coupling Universal joint Flange Cover Rubber coupling Output shaft Engine flywheel
D275A-2
10-11
TORQUE CONVERTER
l
PTO 1
‘C.
A. B. C.
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17MF02008
Mount of hydraulic pump Mount of power train pump Mount of scavenging pump
1. Coupling 2. Seal cage 3. Input shaft [PTO drive gear (61 teeth)] 4. Front housing 5. Idler gear (77 teeth) 6. Idler gear shaft 7. Clutch housing 8. Drive case 9. Turbine IO. Rear housing 11. Stator 12. Pump
10-12
13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Stator shaft Bearing cage Retainer Shaft Transmission input shaft Stator shaft boss Stator clutch housing Return spring Stator clutch plate Stator clutch disc Stator clutch piston Turbine boss Lock-up clutch disc
26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37.
Lock-up clutch plate Lock-up clutch piston Scavenging pump gear (63 teeth) Scavenging pump boss Seal seat Spacer Cover Hydraulic pump gear (57 teeth) Power train pump gear (57 teeth) Drive shaft Cover Cover
37'
z-z
17MF02009
D275A-2
17
OUTLINE 0 The torque converter is a 3-element, singlestage, l-phase torque converter, and it forms a single structure with the transmission. To improve the fuel consumption and ease of operation and to reduce consumption of the engine horsepower, a wet-type, multiple-disc clutch type torque converter lock-up device and a wettype, double-disc stator clutch device are assembled inside it. 0 When the machine is carrying out continuous low-load dozing or grading operations, it is more efficient if the motive power of the engine is transmitted directly to the transmission input shaft. To achieve this, a lock-up clutch actuated by hydraulic pressure is assembled inside the torque converter. When the torque converter is locked up (the pump and turbine form one unit), the oil supplied from the torque converter relief valve does not stop, so the oil leaving the turbine from the pump is given unneeded direction by the stator, and this resists the rotation of the pump and turbine (the oil is churned). To prevent this, a stator clutch similar to the lock-up clutch is built in. This allows the stator to rotate freely when the torque converter is locked up. The oil then moves together with rotation of the pump and turbine; it is discharged from the pump and turbine with little resistance, and is returned to the pump. * The condition for the torque converter to enter the lock-up range and torque converter range are as follows. 0 Lock-up range When both of the following conditions are fulfilled: Torque converter output shaft speed: Above 1170 rpm Transmission set pressure: ‘_ Above 19.5 kg/cm2 0 Torque converter range When either of the following conditions are fulfilled. Torque converter output shaft speed: Below 1110 rpm Transmission set pressure: Below 15 kg/cm2
D275A-2
STRUCTURE 0 Pump (12) forms one unit with coupling (I), shaft (3), clutch housing (7), and drive case (8); and is rotated by the motive force from the engine. l Turbine (9) forms one unit with turbine boss (24) and transmission input shaft (turbine shaft) (17), and is rotated by oil from the pump. 0 Stator (11) forms one unit with stator shaft (13) and stator shaft boss (18), and is locked to rear housing (10) by the stator clutch. 0 The lock-up clutch consists of three parts: clutch plate (26) (meshed with drive case (8)), clutch disc (25) (meshed turbine boss (24)), and clutch piston (27) (that slides inside housing (7) that forms one unit with the drive case). l The stator clutch consists of three parts: clutch disc (22) (meshed with boss (18) that is connected by a spline to stator shaft (13)), clutch plate (21) (supported by a pin to clutch housing (19) and rear housing (IO)), and clutch piston (23) (that slides inside the rear housing). 0 The PTO consists of a drive gear forming one unit with input shaft (3), idler gear (5), scavenging pump drive gear (28), hydraulic pump drive gear (33), and power train pump drive gear (34).
10-13
PATH OF TRANSMISSION
OF MOTIVE
FORCE
1. Lock-up clutch OFF, stator clutch ON When the lock-up clutch is OFF, the connection between drive case (8) and turbine (9) is cut; and when the stator clutch is ON, rear housing (IO) and stator shaft (13) are connected, so stator (11) is locked and the torque converter provides the normal functions of a torque converter. The motive force generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. The motive force from the pump uses oil to rotate turbine (9), and is transmitted to transmission input shaft (17), that forms one unit with the turbine.
7
8
9
10
11
12
13
17
I
Lock-up clutch
Stator Clutch 17MF02010
2. Lock-up clutch ON, stator clutch OFF When the lock-up clutch is ON, drive case (8) and turbine (9) are connected to form one unit; and when the stator clutch is OFF, the connection between rear housing (10) and stator shaft (13) is cut, so stator (11) follows the rotation of pump (12) and turbine (9). The motive force generated by the engine passes through the damper and universal joint, and is transmitted to coupling (1). Input shaft (3), clutch housing (7), drive case (8), and pump (12) rotate as one unit. In addition, the drive case and turbine (9) _ are connected by the clutch, so the oil is 4 not used. The motive force is transmitted directly to the turbine and transmission input shaft (17).
1
3!3
9
Lock-up clutch
110 ,,,I
11
12
13
Stator clutch 17MF02011
10-14
D275A-2
FLOW OF OIL 0 Oil set to within Max. 10 kg/cm2 by the torque converter relief valve flows from port A, passes through the oil hole inside rear housing (IO), and enters pump (12). The pump is always being rotated by the motive force from the engine, so the oil entering the pump is given centrifugal force, and enters turbine (9). The turbine is rotated by the centrifugal force of the oil. The turbine forms one unit with transmission input shaft (17), so the motive force received by the turbine is transmitted to the transmission. The oil leaving the turbine is sent to stator (11) and enters the pump again, but some of the oil passes from the stator through port B and is sent to the oil cooler.
D275A-2
10-15
TORQUE CONVERTER VALVE
A-A Pl \
17MF02013
1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11. 12. 13. 14. 15. 16. 17.
Valve body Torque converter relief valve Valve spring Valve spring Main relief valve Cover Piston Piston spring Piston Stator clutch modulating valve Lock-up clutch modulating valve Cover Piston Piston spring (Small) Piston Valve spring (Outer) Valve spring (Inner)
lo-16
18. Stopper 19. Load piston 20. Cover 21. Cover 22. Valve spring 23. Valve body 24. Lock-up selector valve 25. Piston 26. Cover Lock-up solenoid valve assembly 27. Push pin 28. Valve seat 29. Return spring 30. Valve body 31. NO valve 32. Return spring 33. Cap
Stator clutch pressure pickup port P,: Torque converter relief pressure pickup port P.3‘ Lock-up clutch pressure pickup port P,: Main relief pressure pickup port P10'. Lock-up clutch initial pressure pickup port P11'* Stator clutch initial pressure pickup port P:
D275A-2
E-E
8
E 6
17MF02014
OUTLINE 0 The torque converter valve is installed at the top of the rear housing of the torque converter and consists of the following six types of valves. 1. Main relief valve Main relief valve (5) sets the hydraulic pressure to 25.4 28.0 kg/cm2 in the transmission, steering clutch, brake and torque converter lock-up clutch, and stator clutch circuits. 2. Torque converter relief valve Torque converter relief valve (2) sets the inlet pressure of the torque converter to within 8.7 kg/cm2 to protect the torque converter from abnormally high pressure. 3. Torque converter lock-up valve Lock-up selector valve (24) acts to switch the lock-up clutch and stator clutch ON * OFF.
4. Torque converter lock-up solenoid valve Solenoid valve receives an electrical signal from the lock-up controller and switches the pilot pressure to lock-up selector valve (24). It operates lock-up selector valve (24) and switches the two clutches ON * OFF. 5. Stator clutch modulating valve Modulating valve (10) sets the clutch pressure to 26 - 28 kg/cm* to protect the stator clutch from abnormally high pressure and acts to raise the pressure of oil from lock-up selector valve (24) gradually until it reaches the set pressure. 6. Lock-up clutch modulating valve Modulating valve (11) acts in the same way as stator clutch modulating valve (IO) and sets the clutch pressure to 13 - 14 kg/cm* to protect the stator clutch from abnormally high pressure.
10-17 0
OPERATION OF MAIN RELIEF VALVE The oil from the power train pump passes through the oil filter, and enters port A of the main relief valve. It then passes through orifice a and enters port B. When the oil from the pump fills the circuit, the pressure starts to rise. When the pressure in the circuit rises, the oil entering port B pushes piston (9). The reaction force compresses spring (4), moves main relief valve (5) to the left in the direction of the arrow, and opens ports A and C. When this happens, the oil from the pump is relieved from port A to port C, and flows port C to the torque converter. The pressure in the circuit at this point is 25.4 - 28.0 kg/cm*.
To torque converter
To oil tank
Q From pump
To torque converter
OPERATION OF TORQUE CONVERTER RELIEF VALVE The oil relieved from the main relief valve flows into the torque converter from port C, and at the same time passes through orifice b and enters port D. When the oil fills the torque converter, the pressure starts to rise. If the pressure in the torque converter rises abnormally high, the oil entering port D pushes piston (9). The reaction force compresses spring (3), moves relief valve (2) to the right in the direction of the arrow, and opens ports C and E. When this happens, the oil at port C is relieved to port E, and is drained to the oil tank. The pressure in the circuit at this point is below 8.7 kg/cm*.
To oil tank
From pump F19702005 To torque converter
To oil tank
From pump
lo-18
F19702004
F19702006
D275A-2
OPERATION OF TORQUE CONVERTER LOCK-UP VALVE, SOLENOID VALVE The torque converter lock-up valve supplies oil to switch the lock-up and stator clutch built.into the torque converter ON - OFF. The lock-up valve is actuated by the pilot pressure from the solenoid valve that is actuated when it receive an electrical signal from the lock-up controller. When the lock-up switch on the switch panel at the side of the operator’s seat is pressed ON (the indicator lamp inside the switch lights up), the auto-lock-up system is actuated, and when the torque converter reaches the lock-up range, the lock-up controller, that has received signals from the two sensors, connects the solenoid to the ground and current flows. The hydraulic circuit is switched and pilot pressure is sent to the lock-up valve to lock up the torque conveter. 0
2
E 6
The diagram on the right shows the electrical circuit for the torque converter lock-up system. (For details, see the electrical circuit diagram) The electricity from the battery flows from the relay box to the panel switch. When the lock-up switch is pressed ON, the switch is connected to the ground, and this actuates the relay inside the relay box. The electricity from the battery passes through the pilot lamp and acts as the power source for the lockup controller. In this condition, if both the torque converter output shaft speed detected by the speed sensor is above 1170 rpm, and the transmission modulating pressure detected by the hydraulic sensor is above 19.5 kg/cm* (AND circuit), the controller connects the pilot lamp and solenoid to the ground, and they light up or are excited respectively. If either the torque converter output shaft speed Transm,ss,o is below 1110 ram or the modulating pressure is pressure sens below 15 kg/cm* (OR circuit), the controller cuts the circuit connecting the pilot lamp and solenoid to the ground, and they go out or are deactivated respectively. In other words, when the torque converter %% comes close to the stall range or tries to shift gear, the machine changes to torque converter drive, and when there is continuous light operation, the machine changes to direct drive.
LOC~.“P power LocL-“pgro”“d
J
197FO26
10-19 0
1. Travel in torque converter
drive
:lutch
197FO2023
When the machine is in the torque converter range, the solenoid valve is deactivated, so valves (28) and (31) are pushed to the right in the direction of the arrow by the tension of spring (29). Ports N and M close and ports N and P open.
When this happens, oil from the pump flows ports P and N into port L of the lock-up valve. When the pressure inside the circuit rises, piston (25) is pushed to the left in the direction of the arrow, and the piston pushes out lock-up selector valve (24) to the left.
197FO2024
When lock-up selector valve (24) moves to the left in the direction of the arrow, ports F and G and ports H and K close, and ports F and H and ports G and J open. When this happens, the oil from the pump flows from port F to port H, and becomes the back pressure of the stator clutch piston. When the pressure
1O-20
in At of to
the circuit rises, the stator clutch is engaged. the same time, the oil that is the back pressure the lock-up clutch piston is drained from port G port J, and the lock-up clutch is disengaged.
D275A-2
2. Travel in direct drive
197FO2025
When the machine is in the direct drive range, the solenoid valve is excited, so push pin (27) is pushed to the left in the direction of the arrow and valves (28) and (31) are moved. Ports N and P close and ports N and M open. When this happens, oil from the pump stops at P. The high-pressure oil at port L is drained from port N to port M. When the pilot pressure at port L is lost, piston (25) and lock-up selector valve (24) are returned to the right in the direction of the arrow by the tension of spring (22).
D275A-2
Ports F and H and ports G and J close, and ports F and G and ports H and K open. When this happens, the oil from the pump flows from port F to port G, and becomes the back pressure of the lock-up clutch piston. When the pressure in the circuit rises, the lock-up clutch is engaged. At the same time, the oil that is the back pressure of the stator clutch piston is drained from port H to port K, and the stator clutch is disengaged.
10-21
Operation of stator clutch, lock-up clutch modulating valve 0 The modulating valves are in the circuit between the lock-up selector valve and the inlet ports of the two sets of clutches. When the clutch is switched ON, the modulating valve acts to raise the pressure on the piston gradually until it reaches the set pressure so that the clutch is engaged smoothly, thereby reducing any shock to the torque converter or transmission. j, The following explanation of operation takes the stator clutch as the example, but the operation of the lock-up clutch is the same. However, the oil flow to the clutch during direct drive or torque converter drive is the reverse. 1. Travel in direct drive When the machine enters the direct drive range, the oil at port L of lock-up selector valve (24) returns to the solenoid valve and is drained. When this happens, lock-up selector valve (24) is pushed to the right in the direction of the arrow by the tension of spring (22). Ports F and H close, and ports H and K open, and the oil at port H is drained from port K. When the hydraulic pressure at port H is lost, modulating valve (10) is returned to the right in the direction of the arrow by the tension of spring (16), and ports H and 0 open fully. At this point, the actuating pressure of the stator clutch is drained from port H to port K, and the clutch is disengaged.
Frompump
TO solenoid valve
197FO2026
1o-22
D275A-2
2. Travel in torque converter drive When the machine is in the torque converter drive range, the oil from the solenoid valve enters port L of lock-up selector valve (24) and moves the lock-up selector valve to the left in the direction of the arrow. Ports F and G, and ports H and K close, and ports F and H open. A circuit is then formed from port F through modulating valve (10) to the stator clutch. The oil from the pump flows from port F to the stator clutch, and the pressure in the circuit starts to rise. As the hydraulic pressure in the circuit rises, the oil passing through orifice d in modulating valve (IO) pushes piston (13), and the reaction force moves the modulating valve to the left in the direction of the arrow to throttle ports Q and H. Port Q is connected with port S that applies back pressure to load piston (19), and moves the load piston to the right in the direction of the arrow to compress spring (16). The tension of the spring opens ports Q and H. This operation is repeated intermittently to increase the load of spring (16). While this is happening, the hydraulic pressure gradually increases, and finally stops at the position where ports Q and H are closed to complete the rise in hydraulic pressure. The hydraulic pressure at this point is 26 - 28 kg/cm2. The hydraulic pressure of the lock-up clutch is 13 - 14 kg/cm2.
From pump
D275A-2
197FO2027
_ II
From pump
//I
To solenoid valve
I
To solenoid valve
197FO2028
1 O-23
TRANSMISSION
4
17MF02015
OUTLINE The D275A-2 bulldozer is equipped with a planeand 3-reverse speed” transtary type, “3-forward mission which is a combined structure of a planetary gear mechanism and disc clutches. of the direction and the revolution The rotational output shaft is selected by fixing two transmission disc clutches out of five disc cluthes by means of control valve operation.
1 O-24
No. 1 clutch is fixed in reverse, No. 2 clutch in forward, No. 3 clutch in third speed, No. 4 clutch in second speed, and No. 5 clutch in first speed. Any speed can be selected from three forward speeds and three reverse speeds by fixing either No. 1 or No. 2 clutch and one clutch among No. 3, No. 4 and No. 5 clutches and by combining two of the above.
D275A-2
1
\
5
\
f
:
40/////I 39
8 \
9 \
38
1,s
37
36
35
I 34
/ 33
I 32
‘17
I 31
I 30
l,B
;2
I 29
I 28
I 27
\
/23
f4
;5
36
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41.
Input shaft Transmission valve Front case Rear case Front cover Reverse sun gear (34 teeth) Reverse ring gear (91 teeth) Pinion shaft Reverse planetary pinion (25 teeth) Reverse ring gear (84 teeth) Forward sun gear (41 teeth) Forward planetary pinion (25 teeth) Forward ring gear (91 teeth) Pinion shaft 3rd speed ring gear (91 teeth) 3rd speed planetary pinion (25 teeth) 3rd speed sun gear (41 teeth) 2nd speed ring gear (93 teeth) 2nd speed planetary pinion (23 teeth) Pinion shaft 2nd speed sun gear (47 teeth) No. 5 gear (1 st speed gear) No. 5 clutch piston No. 5 clutch piston housing Output shaft Spacer Block No. 5 clutch spring Seal seat No. 4 carrier Plate No. 2, 3 carrier No. 2, 3 piston housing No. 1 carrier No. 1 piston housing Clutch piston Clutch spring Clutch plate Clutch disc Tie bolt Reverse carrier gear (91 teeth)
Speeds and operating
clutches
Speed
Operating
Neutral
Forward
No. 5 clutch
First speed
No. 2 and
Second
No. 2 and No. 4 clutches
Third
speed speed
No. 5 clutches
No. 2 and No. 3 clutches
Neutral Reverse
clutch
No. 5 clutch
First speed
No. 1 and No. 5 clutches
Second
No. 1 and No. 4 clutches
Third
speed speed
No. 1 and No. 3 clutches
Number of discs and plates on each clutch
Clutch
No.
Number
of plates
Number
of discs
No. 1 clutch
5
5
No. 2 clutch
4
5
No. 3 clutch
2
3
No. 4 clutch
3
3
No. 5 clutch
4
5
4
17MF02016
D275A-2
1 o-25
FUNCTION
OF PISTON
To lock ring gear (7), the discs (39) and plates (38) are brought into close contact. The clutch consists of a clutch piston (36), clutch plates (38), clutch discs (39), pins (42) and piston return springs (37). The disc’s internal teeth engage with the ring gear’s external teeth. The plates, whose notch on the outside diameter engage with pins (42) on housing (35), are locked against the rotating direction. Piston (36) also is locked against the rotating direction.
Clutch engaged (oil pressure is acting) Oil from the control valve flows under pressure through the port in housing (35) to the piston (36). The piston presses clutch plates (38) and clutch discs (39) together, and the frictional force developed stops clutch discs (39) revolution, thus ring gear (7) meshing with the disc’s internal teeth is locked.
3.7
39
4.2
3p
3.!
36C
38
36
35
?5
Clutch disengaged (oil pressure is not acting) When the supply of pressure oil from the control valve is shut off, piston (36) returns to the initial position by the force of piston return spring (37), thus relieving the frictional force between plates (38) and discs (39), making the ring gear (7) free.
F19702010
1 O-26
D275A-2
POWER FIRST
TRAIN FORWARD
OF TRANSMISSION SPEED
I
30 17MF02017
For FORWARD Ist, No. 2 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 2 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks ring gear (13) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engages No. 5 gear (22) and No. 4 ring gear (18) in position. The motive force from the torque converter is transmitted to the input shaft. The rotation of the input shaft is transmitted through sun gear (11) to planet gear (12).
D275A-2
l
Ring gear (13) is locked in position by No. 2 clutch, so planet gear (12) rotates carrier (32), which is on the inside of ring gear (13). No. 5 clutch is also engaged, so the No. 5 gear (22), sun gears (17) and (21), planet gears, ring gears (15) and (18), and No. 4 carrier (30) form one unit, and carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25). Output shaft (25) rotates at the same speed as carrier (32).
1 O-27
6
9
10
11
12
13
15
17
18
21
22
25
17MF02018
For REVERSE Ist, No. 1 clutch and No. 5 clutch are engaged. The motive force transmitted from the torque converter to input shaft (1) is transmitted to output shaft (25). No. 1 clutch is actuated by the hydraulic pressure applied by the clutch piston and locks carrier (34) in position. No. 5 clutch is actuated by hydraulic pressure applied by the clutch piston and engages No. 5 gear (22) and No. 4 ring gear (18) in position. The motive force from the torque converter is transmitted to the input shaft (1). The rotation of the input shaft is transmitted through sun gear (6) to planet gear (9).
1 O-28
l
Carrier (34) is locked in position by No. 1 clutch, so the rotation of planet gear (9) rotates ring gear (IO). Ring gear (IO) rotates in the opposite direction from the input shaft, and it rotates carrier (32). No. 5 clutch is engaged, so the No. 5 gear, sun gears, planet gears, ring gears, and No. 4 carrier form one unit, and carrier (32) rotates as one unit with the gears of No. 3, 4 and 5 clutches to rotate output shaft (25).
D275A-2
TRANSMISSION
1. 2. 3. 4. 5.
Gear shift lever Safety lever F-R spool linkage Speed spool linkage Transmission control
D275A-2
CONTROL
17MF02019
valve
1 O-29
TRANSMISSION
CONTROL VALVE
E-E
17MF02020
Modulating pressure Reducing pressure
1O-30
26-28 20.5 -
22.5
A B C D E F G H J K
From power train pump To speed valve G To speed valve J To forward clutch port (No. 2) To reverse clutch port (No.1) To 1st speed clutch port (No. 5) From reducing valve B To 2nd speed clutch port (No. 4) From reducing valve C To 3rd speed clutch port (No. 3)
D275A-2
A-A
18
K
J
19
H B-B
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Piston Modulating valve Modulating valve load piston Modulating valve spring (Inner) Modulating valve spring (Outer) Quick return valve Cover Piston spring Piston Piston
D275A-2
11. 12. 13. 14. 15. 16. 17. 18. 19.
17MF :02021
Reducing valve Stopper Reducing valve spring Stopper Modulating sleeve spring (Small) Stopper Piston F-R valve Speed valve
10-31
MODULATIING
VALVE
OUTLINE l The modulating valve consists of a modulating relief valve and a quick return valve, and acts to modulates the pressure. l When the gear shift lever is operated to shift gear, the clutch is pushed into close contact by the piston. However, if high pressure is suddenly applied, the piston will suddenly engage the clutch. This will make the machine suddenly start, and it will receive an excessive shock. To prevent this, the modulating valve is installed. When the gear shift lever is operated to shift gear, the pressure on the piston gradually rises to the set pressure and the clutch is engaged smoothly. This allows the machine to start without any shock, thereby improving the durability of the power train and at the same time providing a comfortable ride for the operator. l The figure shows the relationship between the time and the increase in the hydraulic pressure of the modulating valve. For example, when the gear is shifted from Fl and F2, the oil from the pump passes through the speed valve spool, flows to the second clutch and fills the circuit up to the clutch piston port. The time taken for the circuit to be filled up to the clutch piston port is called the “filling time”, and the oil pressure during this time is 0 - 3 kg/cm2. When the circuit up_to the clutch piston port is filled with oil, the oil pressure starts to rise. The time taken for the pressure to rise to the set pressure is called the “built-up time”. The filling time and build-up time together are called the “modulating time”.
Modulating
time
(kg/cm? 30 27 (Set pressure)
2 .? 2 5i is
20-
10 -
I
0
,
(Sec.) 1
0
I
0.5
I
,
,
,
,
1.0
Time 1JMF02022
1 O-32 0
Operation
From pump
1. Immediately after shifting When the transmission shift lever is operated and the clutch is engaged, the passage from the pump to the clutch piston port is opened and the oil flows to the clutch piston port. When this happens, the passage between port B and port D is restricted by orifice b, so a difference in pressure is generated, and quick return valve (6) is moved to the left in the idrection of the arrow by the pressure at port B. This connects port E and drain port F, and removes the back pressure of load piston (3). 2. Pressure starting to rise, during rise When the oil sent under pressue from the pump fills the circuit from port A to the clutch piston port, the hydraulic pressure starts to rise. When this happens, the difference in pressure on the two sides of orifice b of quick return valve (6) is lost, and the quick return valve is moved to the right in the direction of the arrow to close the passage between port E and drain port F. The oil flows form orifice a of modulating valve (2) to port C, and pushes piston (1). Because of the reaction force, the modulating valve compresses springs (4) and (5), and moves to the right in the direction of the arrow to drain the oil from port A to port G. At the same time, the oil flowing from orifice e in quick return valve (6) through the central port passes through orifice d and enters port E. It becomes the back pressure of load piston (3), moves the load piston to the left in the direction of the arrow and compresses springs (4) and (5).
TO clutch cylinder
Drain
6 A
17MF02023
From pump
,E
\
“F
6
To clutch cylinder
Drain
17MF02024
\ 6 17MF02025
D275A-2
1o-33
During rise in oil pressure, completion of rise As the pressure rises, the back pressure of load piston (3) increases. When the movement of the load piston to the left increases, modulating valve (2) closes the passage between port A and port G because of the tension of springs (4) and (5). As the pressure at port C pushing piston (1) increases, modulating valve (2) moves to the right in the direction of the arrow due to the reaction force, compresses springs (4) and (5), and opens the passage between port A and port G. By repeating this operation intermittently, the load of springs (4) and (5) increases and the pressure rises slowly. Finally, load piston (3) contacts the valve body and does not move any further. When this happens, modulating valve (2) stops at the position where the passage from port A to port G is closed, and the rise in hydraulic pressure is completed. The hydraulic pressure at this point is 26 “0 kg/cm2. The oil frbm the pump is relieved through the main relief valve assembled to the torque converter assembly.
A
From
G
\
pump
\
17MF02026
\From PumA /
To
clutchcylinder 17MF02027
1o-34
D275A-2
REDUCING
VALVE
OUTLINE The reducing valve is in the circuit between the modulating valve and the 1st speed valve spool. It reduces the pressure applied to the 1st clutch to 20.5 - 22.5 kg/cm*. The hydraulic pressure in the circuit as a whole is set to 26 - 28 kg/cm* by the modulating valve.
l
From modulating valve
OPERATION 1. Valve OPEN The oil from the modulating valve flows from port A. Some passes through port B and flows to the 1st valve spool and clutch, and at the same time, passes through orifice a and enters port D. The oil also flows from port A through port C, and flows to the 2nd and 3rd spools and the directional spool. When the circuit up to the clutch that has been shifted becomes filled with oil and the pressure rises according to the operation of the modulating valve, the oil entering through orifice a of reducing valve (11) pushes piston (12). The reaction force compresses spring (13) and moves reducing valve (11) slowly to the left in the direction of the arrow in accordance with the rise in the hydraulic pressure, and starts to throttle port B.
C’
To F-R spool To 2nd & 3rd spool
To 1st spool 17MF02028
From modulating valve
13 1
To F-R s;ool To 2nd & 3rd spool
To 1;t spool 17MF02029
2. Valve CLOSED When the pressure in the whole circuit rises further because of the action of the modulating valve, reducing valve (11) moves further to the left and closes the circuit from the modulating valve, so the pressure in the 1st clutch circuit stops rising. The pressure at this point is 20.5 - 22.5 kg/cm*.
From modulating
To F-R spool To 2nd & 3rd spool
To 1st spool 17MF02030
D275A-2
10-35
*
If the pressure in the 1st clutch circuit drops because of leakage from the transmission Iubrication or seal ring, the reaction force of the spring of reducing valve (11) opens the circuit. This raises the pressure to the set pressure of reducing valve (11) and maintains the set pressure. Except for the 1st clutch circuit, the pressure in all the circuits continues to rise to the set pressure of the modulating valve. The 1st clutch is farthest from the control valve, and the piping to the cylinder is longer, so it takes a longer time for the oil to fill the piping. For this reason, even when the gearshift lever is in neutral, oil still flows to the 1st clutch. Therefore, when moving the gearshift lever from neutral to Fl, it is only necessary for the oil from the pump to fill the FORWARD clutch. When the gearshift lever is moved from Fl to F2, the FORWARD clutch is already filled with oil, so the oil from the pump only needs to fill the 2nd clutch. By using the oil in this way, the time lag when shifting gear is reduced.
From reducing valve
1st clutch piston 17MF02031
1 O-36
D275A-2
TRANSMISSION
LUBRICATION
RELIEF VALVE
A-A
1. Valve body 2. Lubrication relief spool a. Lubrication pressure measurement
D275A-2
561 FO3032
plug
FUNCTION l This valve is installed to the right transmission and prevents abnormal the transmission lubrication circuit. Cracking pressure: 2.7 kg/cm2
side of the pressure in
1o-37
SCAVENGING (BAR63
+
PUMP
BARZOO)
7
197 F058A
A. Discharge port B. Small pump suction C. Large pump suction 1. Small pump 2. Large pump
port port
OUTLINE This pump is installed on the lower of the PTO l case, and consists of a small pump and a large l
pump. The small pump sucks the torque converter case oil and the large pump sucks the steering case oil, and this oil is returned to the oil tank.
Discharge
pressure (kg/cm2)
At rated speed
1 O-38 0
(rpm)
OIL STRAINER
17MF02032
1. 2. 3. 4. 5.
Cover Spring Magnet Screen Case
A. From oil tank B. TO power train pump and lubrication
pump
Passage flow
600 a/min
Screen mesh
80
D275A-2
OUTLINE l The strainer is installed on the front and left of the power train unit. l Open the fender located at the front of operator’s seat, and maintain the strainer. l The oil from the oil tank is filtered by screen (4), and is sucked by the power train pump and the lubrication pump.
1o-39
POWER TRAIN
OIL FILTER AND LUBRICATION
OIL FILTER
z 17MF02033
1. 2. 3. 4. 5.
Cover Element Body Valve (Setting Spring
pressure:
I.4 kg/cm*)
A. Inlet B. Outlet
Cracking
pressure
1.4 kg/cm*
Passage flow
273 Illmin.
Filter ability
30 microns
1O-40
OUTLINE The two filters are the same part, and are installed on the front of power train unit. Open the fender located at the right and front of operator’s seat, and maintain the filter. The oil from the oil tank is sucked by the power train pump and the lubrication pump through the strainer, and is sent to each filter. If element (2) is clogged or the oil temperature is low, the oil pressure increase, so valve (4) is installed to prevent the filter from breaking.
D275A-2
STEERING
UNIT
II% =
--
0
---
----
17MF02034
OUTLINE The steering unit consists of the transfer, bevel gear shaft, steering clutch, and steering brake.
1 O-42
D275A-2
A-A
F-F
E-E 17MF02035
D-D
1. 2. 3. 4.
Transmission Breather Steering unit Torque converter
output
shaft speed sensor
A. Mount of steering control valve B. Center of bevel gear shaft C. Center of crank shaft D. Center of bevel pinion
D275A-2
1o-43
TRANSFER,
BEVEL PINION
17MF02036
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Input shaft Drive shaft Drive gear (33 teeth) Rear cover support Torque converter output Bearing cage Drum Cover Bearing cage Driven gear (34 teeth) Bevel pinion Bevel gear
1o-44
shaft speed sensor
OUTLINE l The transfer and bevel pinion are installed at the rear inside the steering case and receive the motive force from the transmission output shaft with input shaft (1). The transfer consists of drive gear (3) and driven gear (11). It reduces the speed of the motive force from input shaft (1) and transmits it to bevel pinion (12). Drive shaft (2) rotates drum (8), which sends a pulse signal to torque converter speed sensor (6).
D275A-2
OUTLINE Bevel gear shaft The motive force from the engine - torque converter -+ transmission -, transfer enters the bevel gear system. The bevel pinion and bevel gear are meshed and act both to reduce the speed of rotation and to send to the power at right angles to the left and right. The bevel gear system uses spiral bevel gears for the bevel pinion and bevel gear, and a splash-type lubrication system is employed that uses the oil from the power train oil cooler. The bevel gear system consists of the following: bevel gear (17) that meshes with the bevel pinion, bevel gear shaft (16). two steering shafts (15) that are connected to the bevel gear shaft by a spline, the bearing that supports the bevel gear shaft, and bearing cages (14) and (18). Steering clutch l The steering clutches are connected by a spline to the left and right steering shafts, and act to engage or disengage the motive force to the final drive, thereby changing the direction of travel of the machine. l The steering clutches are wet, multiple-disc clutches with a spring booster. They are interconnected with the brakes and are hydraulically actuated by a steering valve that is actuated when the steering lever is operated. A forced lubrication system is employed in which the oil from the power train oil cooler passes through the passage inside the steering case, enters the housing and cage, and is then sent to the discs and plates. l The steering clutch consists of the following: hub (19) that is connected with the steering shaft by a spline, disc (23) that meshes with the hub, plate (22) and housing (27) that are mated at the outside circumference with torque pin (24), piston (25) that presses the discs and plates together, spring (26) and stopper (20), and cage (28) that supports these parts. Housing (27) and cage (28) are connected with brake hub (12), and send the motive force from the bevel gear through the brake hub to output shaft (1).
D275A-2
Steering brake l The steering brakes are connected with the left and right steering clutches, and act to brake the machine or change the direction of travel by braking or connecting the motive force from the steering clutches to the final drive. l The steering brakes are wet, multiple-disc clutches with a spring booster. They are interconnected with the brakes and are hydraulically actuated by a steering valve that is actuated when the brake pedal and steering lever are operated. A forced lubrication system is employed in which the oil from the power train oil cooler passes through the passage inside the steering case, enters the housing and cage, and is then sent to the discs and plates. The steering brakes are designed so that when the engine has stopped, the back pressure of the brake piston drops and the brake are applied without the brake pedal being depressed. However, when the engine is started again, the brake is released as the hydraulic pressure inside the circuit rises, so the brake pedal must always be locked. l The steering brakes consist of the following: clutch housing (27), hub (12) that is connected with cage (28) and output shaft (I), disc (10) that is meshed with the hub, plate (8) and housing (5) that are mated at the outside circumference by torque pin (7), piston (6) that presses the discs and plates together, spring (4) and stopper (II), and cage (3) that supports these parts. Housing (5) and cage (3) are secured to the steering case.
1o-47
OPERATION
OF STEERING
CLUTCH
1. When steering clutch is engaged When the steering lever is at the neutral position, the steering valve is also at the neutral position, so no back pressure is applied to piston (25). In this condition, the piston is pushed to the right by the tension of spring (26), and disc (23) and plate (22) are brought into close contact with stopper (20). The stopper is connected with housing (27) by torque pin (24). Therefore, the motive force from steering shaft (15) is transmitted from hub (19) to housing (27) through the discs and plates that are held together. The motive force is then transmitted from brake hub (12), which forms one unit with the housing, through the output shaft (1) to the final drive.
1
12
27 26
25
24
23
22
20
19
15
F19702025
2. When steering clutch is disengaged When the steering lever is pulled, the steering valve is switched and oil enters the area behind piston (25). When the hydraulic pressure rises, it pushes the piston to the left, and compresses spring (26) to release the pressure holding disc (23) and plate (22) together. When this happens, the motive force from steering shaft (15) rotates only hub (19) and the disc, so the motive force is not transmitted beyond housing (27) and does not go to the final drive. When the steering lever is released, the steering valve opens the drain circuit, and the tension of spring (26) pushes piston (25) back to its original position to return the clutch to the engaged condition explained is Section 1. When the left steering clutch is disengaged, the motive force is transmitted only to the right steering clutch, so the machine turns to the left (travels to the left).
F19702026
1 O-48
D275A-2
OPERATION
OF STEERING
BRAKE
1. When steering brake is released When the steering lever and brake pedal are at the neutral position, the steering valve is also at neutral, so the steering clutch is engaged, and oil enters the back pressure port of steering brake piston (6). When the hydraulic pressure rises, it pushes the piston to the left, compresses spring (4), and releases the pressure holding disc (10) and plate (9) together. When this happens, the motive force transthe shaft (15) through mitted from steering steering clutch to housing (27) is transmitted from hub (12) to output shaft (I), and goes to the final drive.
1
7
6
5
4
lb
;1
-27
1.5
F19702027
2. When steering brake is applied (steering lever pulled) lever is pulled fully, the When the steering and the steering valve is switched steering At the same time, the oil clutch is disengaged. back pressure to piston (6) is conapplying nected to the drain circuit. the piston is pushed to the In this condition, right by the tension of spring (4), and disc (10) and plates (9) are brought into close contact with stopper (11). The stopper is connected to case (5) by torque pin (7), so it is locked in position. even if the steering clutch is disenTherefore, gaged, the rotation of output shaft (I), that is the rotation of hub (12) caused by inertia, is stopped when the disc and plate are pushed into contact. The hydraulic force applied to spring (4) is controlled by the amount that the steering lever is pulled, so it is possible to adjust the braking speed the turning controlling force, thereby and turning radius.
Y
D275A-2
10
1’1
li
F1970202%
1o-49
3. When steering brake is applied (brake pedal depressed) When the brake pedal is depressed, the steering valve is switched, and the oil applying back pressure to piston (6) is connected to the drain circuit. The steering clutch remains engaged, and only the brake is actuated to stop the rotation of output shaft (1).
1
5
4
I
6
27
15
I#I II I
10
1 O-50
7
1’1
1’2
F19702029
D275A-2
STEERING CONTROL
17MF02038
1. 2. 3. 4. 5. 6.
D275A-2
L.H. steering lever R.H. steering lever Brake lock lever Brake pedal Brake pedal return spring Steering control valve
10-51
STEERING CONTROL VALVE
z 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
197FO2045
‘CL
Plug Return spring Piston Valve body R.H. steering valve Modulating spring Shaft ass’y Cover Return spring R.H. brake valve Modulating valve
1 o-52
12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Shaft ass’y Guide L.H. brake valve L.H. steering valve Plug Return spring Piston Seat Check valve Spring
To R.H. steering clutch piston port B. To R.H. steering brake piston port C. To steering case D. From power train pump E: To L.H. steering brake piston port F: To L.H. steering clutch piston port CL: Plug for L.H. steering clutch pressure CR: Plug for R.H. steering clutch pressure BL: Plug for L.H. steering brake pressure BR: Plug for R.H. steering brake pressure A.
D275A-2
197FO2046
OUTLINE The steering control valve consists of two steering valves and brake valves, and is in the circuit between the steering clutch and brake pistons and the power train pump passing through the main relief valve. When the steering lever is pulled, the steering clutch is disengaged. If it is pulled further, the brake is engaged and the machine stops. When the lever on one side is pulled, it is possible to adjust the angle of turning to give gradual turns or sharp turns. If the brake pedal is depressed, the brake is engaged and the machine stops.
D275A-2
These operations are made possible by switching the steering control valve which is interconnected with the lever and pedal. The steering control valve sends oil from the power train pump to the steering clutch and brake, and operates the disc clutch of each.
1o-53
VALVE CONTROL
LEVER
D-D
I97FO72
22. 23. 24. 25. 26. 27. 28. 29.
R.H. steering L.H. and R.H. Lever box Roller R.H. steering Brake lever L.H. steering L.H. steering
1o-54
lever shaft brake lever shaft
lever lever lever shaft
OUTLINE l The steering control valve is operated by lever shafts (22) and (29) and levers (26) and (28) interconnected with the steering lever in the operator’s compartment, and lever shaft (23) and lever (27) interconnected with the brake pedal. l The steering valve and brake valve inside the steering control valve are interconnected by cam (25) of levers (26) and (28) to enable the steering lever system to be operated.
D275A-2
OPERATION 1. When steering lever, brake pedal are at neutral (clutch engaged, brake released)
To toI que converter val ve, To tri lnsmission control valve
flnnnnn
From
F19702030
l
When the steering lever and brake pedal are at levers (26), (27), and neutral (not operated), (28) are also at neutral, and the oil ports of each valve are opened or closed by the tension of the spring. The oil from the power train pump passes through the main relief valve and enters port A of check valve (20). Some of the oil entering port A enters port B of left and right steering valves (5) and (15), and stops. When this happens, the oil from the back pressure port of the clutch piston returns from port C to drain port H, and the clutch is engaged by the tension of the clutch spring.
D275A-2
The rest of the oil pushes open check valve (20), enters port E of left and right brake valves (10) and (14), and then flows from port F to the back pressure port of the brake piston. When the hyin the circuit rises, the piston draulic pressure the brake spring, moves to the left, compresses and the brake is released.
1o-55
2. When steering lever is pulled (clutch disengaged, brake released)
From power train pump
F19702031
When the left steering lever is pulled, roller (25) of lever (28) pushes shaft (7) to the left and compresses modulating spring (6). The reaction to this moves steering valve (15) to the left. When this happens, the circuit between port C and drain port H is closed, and the circuit between ports B and C is opened. The oil from the power train pump flows from port B and enters port C. Some of the oil flows to the clutch piston port and becomes the back pressure, and the rest of the oil passes through orifice b and enters port D. The oil entering port D pushes piston (3). and the reaction compresses spring (6) and moves valve (15) to the right. This closes the circuit between ports B and C, so the oil cannot flow beyond port C. As a result, the hydraulic pressure does not rise and is maintained at the same level. If the steering lever is pulled further, the above operation is repeated, and when roller (25) of lever (28) reaches the position where it contacts shaft (12) of the brake valve, the hydraulic pressure beyond port C rises to the set pressure of the main relief valve (26 kg/cm*), and the clutch is fully disengaged.
1 O-56
A
The hydraulic pressure beyond port C is determined by the tension of modulating spring (6), which changes the load in accordance with the amount the steering lever is operated. Therefore, if the steering lever is moved a short distance, the hydraulic pressure beyond port C is set low and the clutch remains partially engaged, and if it is moved a large distance, the hydraulic pressure is set high and the clutch is fully disengaged.
D275A-2
3. When steering lever is pulled (clutch disengaged, brake applied)
18
From
3
20
14
11
12
pump
F19702032A
When the left steering lever is pulled further from the condition in Item 2, roller (25) of lever (28) pushes shaft (12) to the left and compresses modulating spring (11). The reaction to this moves brake valve (14) to the left. When this happens, the circuit between ports E and F is closed, and the circuit between port F and drain port H is opened. The oil from the power train pump flows from port A, pushes open check valve (20), and enters port E, where is stops. Some of the oil that flows to the brake piston port and becomes the back pressure flows from port F and is drained to port H, and the rest of the oil passes from port F through orifice c and enters port G. However, when the oil beyond port F is drained to port H and the hydraulic pressure drops, the oil enters port G and pushes piston (18). The reaction force pushing valve (14) to the left also becomes smaller, so valve (14) is returned to the right by the tension of return spring (17). This closes the circuit between ports F and H, so the hydraulic pressure beyond port F does not drop, but is maintained at the same level.
D275A-2
If the steering lever is pulled further, the above operation is repeated, and when it reaches the end of its travel, the brake is fully applied. The hydraulic pressure beyond port F is determined by the tension of return spring (17) which changes the load in accordance with the amount the steering lever is operated. Therefore, if the steering lever is moved a short distance, the hydraulic pressure beyond port F is set high and the brake is partially applied, and if it is moved a large amount, the hydraulic pressure is set low and the brake is fully applied. Port J is connected to port F, and this reduces the operating force of lever (28) that pushes out shaft (12) to the left. However, the hydraulic pressure at port J, that is, the booster pressure, follows the hydraulic pressure of port F that changes in accordance with the change in the amount that the steering lever is moved, so the operating force of the steering lever also changes.
1o-57
4. When brake pedal is depressed (clutch engaged, brake applied)
To torque converter To transmission
valve,
cs
From power train pump
~--fCG%
F19702033
When the brake pedal is depressed, the two rollers (25) of lever (27) push left and right shafts (12) to the left, and left and right brake valves (IO) and (14) are actuated in the same way as in Item 3. Therefore, the hydraulic pressure is set in accordance with the amount the brake pedal is depressed, and it is possible to adjust the braking effect. The left and right steering levers are not being operated, so the clutch is engaged.
1 O-58
D275A-2
FINAL DRIVE
17MF02039
GENERAL The reduction system consists of one stage using spur gears and another using planetary gears. The lubrication system uses the gears to splash up the oil in the final case to lubricate all the parts. The rotating and sliding parts of the sprocket have floating seals (19) to prevent dirt from getting in from the outside, and to prevent the oil from leaking out.
1 O-60
l
Between inner body (15) and outer body (13) of the sprocket and sprocket boss (12), there are rubber bushings (20) installed equally spaced around the circumference at ten places on each side. These rubber bushings are cylindrical with a two layer construction of rubber and metal. The rubber bushings are deformed when there is external force such as impact force of drawbar pull during operations. This reduces the load on the final drive components. In addition, seal (14) is assembled to separate rubber bushings (20) completely from the outside in order to prevent the entry of dirt or water from outside.
D275A-2
17MF02040
1. 2. 3. 4. 5. 6. 7. 8.
Bearing cage Final drive case No. 1 pinion (20 teeth) No. 1 gear hub No. 1 gear (77 teeth) Cover Ring gear (67 teeth) Planet gear (25 teeth)
D275A-2
9. 10. 11. 12. 13. 14. 15. 16.
Cover Sun gear (17 teeth) Sprocket teeth Sprocket bos Outer body Seal Inner body Cover
17. 18. 19. 20. 21. 22. 23.
Hub Carrier Floating seal Rubber bushing Wear guard Shaft Pivot shaft
lo-61
TRANSMISSION
OF MOTIVE
FORCE
The motive force from the bevel gear shaft and steering clutch is transmitted to No. 1 pinion (3). It is then transmitted through No. 1 gear (5) and No. 1 gear hub (4) to rotate sun gear (10). The rotation of sun gear (10) is transmitted to planet gear (8). However, ring gear (7), which is meshed with the planet gears, is fixed to cover (9). Therefore, planet gear (8) rotates on its own axis and moves along the ring gear in orbit around sun gear (10). The rotation of sun gear (10) is transmitted to carrier (18), and then passes through hub (17) to rotate inner body (15). The inner body rotates in the same direction as sun gear (10). Rubber bushing (20) is installed between inner body (15) and outer body (13) and sprocket boss (12), so the rotation of inner body (15) is transmitted through rubber bushing (20) to outer body (13), sprocket boss (12), and sprocket teeth (11).
17MF02041
1 O-62
D275A-2
MAIN FRAME
I
I
A-A
B-B
X
1. Main frame
D-D 17MF02042
D275A-2
1 O-63
A-A
1. 2. 3. 4. 5. 6.
Idler Idler yoke Carrier roller Track frame Sprocket Track roller (Single flange)
1 O-64
17MF02043
7. 8. 9. 10. 11. 12.
Track roller (Double flange) Track roller guard Cap Bushing Pivot shaft Bushing
D275A-2
RECOIL SPRING
B-B
17MF02044
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Idler yoke Front pilot Recoil spring Piston shaft Track frame inner cylinder Track frame outer cylinder Rear pilot Adjustment cylinder Adjustment valve Outer cylinder bushing
D275A-2
OUTLINE l
Recoil spring (3) is assembled inside track frame inner cvlinder (5). One end is connected to idler yoke (I) through front pilot (2), and the other end is connected to inner cylinder (5) through rear pilot (7). Adjustment cylinder (8) is fixed to track frame outer cylinder (6), and moves inner cylinder (5) backwards or forwards by pumping in or releasing grease from valve (9) to adjust the track tension.
1O-65
SUSPENSION
(l/Z)
Serial No. : 10001 - 10127
----,
../-___.--.--------
___.-~’
__
\..
rT-cM_I17MF02045
1. 2. 3. 4. 5. 6. 7.
Pivot shaft assembly Equalizer bar Seal cage Pivot shaft Thrust plate Cover Thrust plate
8.
Joint
1O-66 @
9. 10. 11. 12. 13. 14. 15.
Side pin Lock plate Bushing Center pin Bolster Small cushion Large cushion
D275A-2
[Right side of pivot shaft]
[Left side of pivot shaft] *
For machines with the dual tilt specification, the right side is also the same.
c
I)
Front
Rear 6
B-B
\
11
Y 17MF02046
D275A-2
1 O-67
Serial No. : 10128 and up
17MF02045
1. 2. 3. 4. 5. 6. 7. 8.
Pivot shaft assembly Equalizer bar Seal cage Pivot shaft Thrust plate Cover Thrust plate Joint
1 O-67- 1 @
9. 10. 11. 12. 13. 14. 15.
Side pin Lock plate Bushing Center pin Bolster Small cushion Large cushion
Left
Ei
z
side
A-A of
pivot
shaft
Right
side
of
pivot
shaft
c Rear
Front
z
B-B
SBDOl511
10-67-2 @
SUSPENSION
(2/2)
/ 13
-
/ 16
REAR 17
-'-
E-E
D-D
16. 17. 18.
'16
F-F
17MF02047
Rod Rod pin Bushing
1 O-68
D275A-2
HYDRAULIC
PIPING
BLADE
17MF02048
1. Blade tilt cylinder 2. Blade lift cylinder 3. Hydraulic pump 4. Blade lift valve 5. Ripper low valve 6. Hydraulic tank 7. Hydraulic filter 8. Ripper high valve
D275A-2
1O-69
VARIABLE
MULTIPLE
SHANK
RIPPER
17MF02049
9. 10.
Ripper tilt cylinder Ripper lift cylinder
1O-70
D275A-2
VARIABLE
GIANT
RIPPER
198FlO89
9. 10. 11. 12.
Ripper tilt cvlinder Ribber lift cilinder Pin puller cylinder Pin puller solenoid valve
10-70-l 0
HYDRAULIC BLADE
CONTROL
CONTROL
/ 197FO2069
1. Blade control 2. Lock lever
lever
A. RAISE B. LOWER C. FLOAT D. L.H. TILT E. R.H. TILT
D275A-2
1o-71
BLADE
CONTROL
(For dual
tilt
dozer)
17MF02050
1. Blade control lever IA. Dual tilt switch 1 B. Pitch switch 2. Lock lever A. B. C. D. E.
Dual tilt l Dual l Dual l Pitch l Pitch
operation left tilt right tilt back dump
: : : :
Switch Switch Switch Switch
IA IA 1B 1B
+position fposition fposition -l-position
D E D E
RAISE LOWER FLOAT L.H. TILT R.H. TILT
1 O-72
D275A-2
RIPPER CONTROL
3. 4.
Ripper control Lock lever
lever
A. RAISE B. LOWER C. TILT ON D. TILT BACK
D275A-2
1o-73
HYDRAULIC
CIRCUIT SYSTEM
ENGINE
HYDRAULIC
RUNNING,
CONTROL
LEVER IN “HOLD”
I-%
M I#
33 /
1
t
1o-74
I
.
17MF02051
D275A-2
HYDRAULIC
CIRCUIT DIAGRAM
ENGINE
HYDRAULIC
RUNNING,
C6NTROL
LEVER IN “HOLD”
Ripper high val\ie
Blade-tilt
ripper
low valve
.-
r
34
34
1. 2. 3. 4. 5. 6. 7. 8. 9. IO. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
35
-_
I i
Pi3Y
I
2’
I
I
r-----
--
-------
!
!
j
[
5 Blade
lift valve
_
_
-
I
7
i___________________--______
I
l-l
1:I‘I
‘2
----------------_____ &I -t------
I
12
1
-I
I
D-&__ _-_
----------7
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1
!
!
-
23. 24. 25. 26. 27.
,I I(
0
Fr 11
f-----
28. 29. A
-
/ \
Lower
-1
e -
)(
L ----
-
X
B Float 0
-II-
100 -1
r+
Z
I
-’
\
, .
/ \
(Engine
at 1915 rpm)
30. 31. 32. 33. 34. 35. 36. 37.
Hydraulic tank Hydraulic pump Main relief valve Check valve Check valve Demand spool Blade lift valve spool Shuttle valve Shuttle valve Blade lift suction valve Quick drop valve Blade lift cylinder Main relief valve Check valve Blade tilt valve spool Check valve Ripper tilt valve spool Check valve Ripper lift valve spool Shuttle valve Blade tilt cylinder Fixed differential pressure valve (for ripper tilt) Shuttle valve Fixed differential pressure valve (for ripper tilt) Shuttle valve Ripper tilt valve spool Fixed differential pressure valve (for ripper lift) Shuttle valve Fixed differential pressure valve (for ripper lift) Shuttle valve Ripper lift valve spool Check valve Ripper lift suction valve Ripper tilt cylinder Ripper lift cylinder Ripper tilt suction valve Hydraulic filter
17MF02052
D275A-2
1o-75
FOR DUAL TILT DOZER ENGINE RUNNING, HYDRAULIC
CONTROL
LEVER IN “HOLD” 38 A
1
Y
Wooer hiah valve
-
Blade-tilt
ripper
low valve
.-
36
r-l-i-----+
I
~
-
---3
-5-z ---
I
vi
36
L--J
I
k#
Low
__~&._*
1+- + r--
11
Tilt
1. 2. 3. 4. 5. 6. 7. 8. 9. IQ. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
bi
on
+{____T= ++-_----____+l,9~
_.IA
Bz,
0 I.
4,
A2
i-i
37
I4 1 -4
IZ
I 1
I t
-_c_--_--
I 11%
_---_---I
I
:
*f-R-
-4 .-1
---__----_--
--__
---__----
____
--1
-----_------~-----_----------~~~ -_-_ -7
r-----
f
----7
1 Blade
,
I---_-__ -t------
2
--
-i,
0
-0
I(
g.E+( I
0
I
I----,,
I
1O-76
_
______ __ _____ -------~~--------____
_
I
,
-
-_ ______
_----------1 _ __---__--+---__
t
---I! “-+--_
T
f
5
P‘2
-25. 26.
I--,
I
I
\ I
P
*
I
27. 28. 29. 30. 31.
E E
11
12.
liftvalve
&I
12
4l
L
_ _
1 -_
I 5
L ______ -_ ________----_____
-----___A
\I
. I
I I
/ Ll
32. 33. 34. 35. 36. 37. 38. 39.
Hydraulic tank Hydraulic pump Main relief valve Check valve Check valve Demand spool Blade lift valve spool Shuttle valve Shuttle valve Blade lift suction valve Quick drop valve Blade lift cylinder Main relief valve Check valve Blade tilt valve spool Check valve Ripper tilt valve spool Check valve Ripper lift valve spool Shuttle valve Dual tilt solenoid valve Blade pitch solenoid valve Blade tilt cylinder Fixed differential pressure valve (for ripper tilt) Shuttle valve Fixed differential pressure valve (for ripper tilt) Shuttle valve Ripper tilt valve spool Fixed differential pressure valve (for ripper lift) Shuttle valve Fixed differential pressure valve (for ripper lift) Shuttle valve Ripper lift valve spool Check valve Ripper lift suction valve Ripper tilt cylinder Ripper lift cylinder Ripper tilt suction valve Hydraulic filter
17MF02053
D275A-2
HYDRAULIC
TANK
-I----“\
1 i
I
=:_._.-. LL.il_.‘,
17MF02054
7. 2. 3. 4. 5. 6. 7. 8.
Oil lever gauge Oil filler Valve Hydraulic oil filter Baffle Tube Blade tilt, ripper low valve Blade lift valve
D275A-2
P : P, : A : B: A, : B, : A,: B, : A,: B, : T:
From small pump From large pump To blade lift cylinder head To blade lift cylinder bottom To blade tilt cylinder bottom To blade tilt cylinder head To ripper tilt cylinder head To ripper tilt cylinder bottom To ripper lift cylinder head To ripper lift cylinder bottom From ripper high valve
1o-77
BLADE LIFT CONTROL VALVE
I97FOSS
OUTLINE l Demand valve (14) is assembled in the blade lift valve, and the oil from the two hydraulic pumps is merged by check valve (4). The demand valve uses the oil from the two hydraulic pumps effectively: the oil from the large pump becomes the pilot pressure; the oil from the ripper circuit and the blade lift circuit through shuttle valve (18B) becomes the pilot pressure.
1 O-78
P, P, A B T
: From large pump From small pump To blade lift cylinder head To blade lift cylinder bottom To hydraulic tank
: : : :
D275A-2
1'1
li
B-B
io
A-A
18 18
E-E
1. 2. 3. 4. 5. 6. 7.
Valve body Check valve spring Check valve Check valve (for small pump) Check valve spring Blade lift valve spool Shuttle valve seat (plug)
D275A-2
F-F
8. 9. 10. 11. 12. 13. 14.
Shuttle valve ball Return spring Detent spring Detent ball Detent shaft Demand valve spring Demand valve spool
15. 16. 17. 18. 18A. 18B.
I97FO99
Suction valve spring Suction valve (for LOWER side) Suction valve (for RAISE side) Main relief and shuttle valve assembly Main relief valve Shuttle valve
1 o-79
MAIN
RELIEF VALVE,
SHUTTLE
VALVE
z
A-A
1. 2. 3. 4. 5. 6. 7.
Adjustment screw for main relief pressure Sleeve Main relief valve spring Main relief valve poppet Valve seat Plug Valve body
1 O-80
8.
197FlOO
Piston
9. Shuttle valve 10. Shuttle valve spring
PL. From shuttle valve in ripper valve PB. From shuttle valve in blade lift valve P To demand valve pilot port TY’ To hydraulic tank
D275A-2
OUTLINE The main relief valve is in the circuit between l the hydraulic tank and the ripper circuit and blade lift circuit (which passes through shuttle valve (9)). The main relief valve sets the hydraulic pressure in the large pump circuit that is, the blade lift cylinder to 210 kg/cm*. The shuttle valve is in the circuit between the l demand valve (which passes through the main relief valve) and the blade lift and ripper circuit. It selects the two circuits to apply pilot pressure to the demand valve. In other words, it selects either the blade lift circuit or the ripper circuit. When the work equipment is not being used (control lever at HOLD), the tension of spring (IO) in the shuttle valve connects the pilot port of the demand valve and the blade lift circuit.
Operation of main relief valve Chamber A forms a pump circuit and chamber l C forms a tank drain circuit. The oil flows into chamber B through the main relief valve orifice to keep the chamber filled. Pilot valve is set in the valve seat. 204FO81
l
l
If the pressure in chamber B reaches the pilot valve spring force (set pressure), the pilot valve moves, allowing the oil in chamber B to flow into chamber C through chamber D. In addition, the oil flows from chamber A to B through orifices. If the oil flows through the orifice of valve, a differential pressure occurs between the chambers A and B, moving valve to the right. This allows the oil in chamber A to flow into chamber C.
D275A-2
204FO82
204FO83
lo-81
BLADE TILT CONTROL AND RIPPER LOW VALVE
197FIOI
OUTLINE l The ripper low valve consists of a 3-spool valve. It acts to reduce the hydraulic loss in the independent blade tilt circuit when the blade is being tilted. In the ripper lift and tilt circuits, the pilot pressure switches the demand valve when the control lever is operated. At the same time, the oil which passes through the low valve operates the ripper high valve (fixed differential pressure type valve) at the rear, and improves the response of the ripper.
1 O-82
P : From small pump A, : To blade tilt cylinder bottom B, : To blade tilt cylinder head A, : To ripper tilt cylinder head B, : To ripper tilt cylinder bottom A, : To ripper tilt cylinder head B, : To ripper tilt cylinder bottom C, : To demand valve P,: To shuttle valve in blade lift valve
D275A-2
B-B
D-D 197FlO2
1. 2. 3. 4. 5. 6. 7.
Blade tilt valve spool Ripper tilt valve spool Ripper lift valve spool Valve body Valve joint Return spring Bolt
D275A-2
8. Adjustment screw for main relief pressure 9. Sleeve 10. Main relief valve body 11. Poppet spring 12. Main relief valve poppet 13. Valve seat 14. Main relief valve spring
15. Main relief valve 16. Valve seat 17. Check valve 18. Check valve spring 19. Valve seat 20. Shuttle valve seat (plug) 21. Shuttle valve ball 22. Shuttle valve seat
1 O-83
RIPPER HIGH VALVE
61-l \
BZ-1
/
AI-2
AZ-2
: PAI : PB, : PA2 : P : P
197FlO3
1 O-84
A::, B,., A,, B,., A,., B,., A,., B,.,
: : : : : : : :
From large pump From low valve tilt on From low valve tilt back From low valve ripper raise From low valve ripper lower To left tilt cylinder bottom To left tilt cylinder head To right tilt cylinder bottom To right tilt cylinder head To left tilt cylinder bottom To left tilt cylinder head To right tilt cylinder bottom To right tilt cylinder head
D275A-2
10
9
A-A
,a
B-B
D-D 197FlO4
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Valve body Shuttle valve seat Shuttle valve ball Valve body Plug Fixed differential pressure Fixed differential pressure Fixed differential pressure Fixed differential pressure Fixed differential pressure
D275A-2
valve spring valve valve valve valve
11. Plug 12. Check valve spring 13. Check valve 14. Valve return spring 15. Plug 16. Ripper lift valve spool 17. Suction valve spring 18. Suction valve 19. Ripper tilt valve spool
1 O-85
RIPPER TILT SUCTION
VALVE
I
C
1. 2. 3. 4. 5.
Valve body Valve Spring Stopper Plug
1 O-86
A-A 17MF02055
A. To hydraulic tank B. From ripper high valve C. To ripper tilt cylinder bottom
D275A-2
OPERATION 1. Blade lever at HOLD, ripper lever at HOLD
I.
,.Gz
II’
t. r.
‘a
R. -
17MF02056
1O-88
D275A-2
l
When the blade lever is at the HOLD position, blade lift spool (5) closes the circuit from port B to ports C and D, and opens the circuits of ports H and E and ports J and F. Blade tilt spool (16) closes the circuit from port B, to ports C, and D,. Therefore, the circuits for blade lift cylinder (9) and blade tilt cylinder (17) become closed circuits, and the cylinders are held in the same position. If the ripper lever is placed at the HOLD position, ripper tilt spool (19) closes the circuit from port B, to ports C, and D4, and ripper lift spool (21) closes the circuit from port B, to ports C, and D,. Therefore, the circuits for ripper tilt cylinder (45) and ripper lift cylinder (33) become closed circuits through the two ripper valves, and the cylinders are kept in the same position. If the engine is started in this condition, the oil from the large pump enters port A of the blade lift valve. Some of the oil pushes open check valve (3) and enters port B where it stops. The rest of the oil passes through orifice a of demand valve (I), and enters ports L and M. (The demand valve is pushed to the right by the tension of spring (2).) The oil from the large pump flows to the blade lift valve, but it also enters port A, of the ripper Hi valve, pushes open the two check valves (23) and (35), then enters ports B, and B,, and stops. The oil from the small pump flows from port A, of the ripper Lo valve and blade tilt valve to ports A,, A,, and A,. Some of the oil pushes open check valves (15), (18), and (20), then enters ports B,, B,, and B,, and stops. The rest of the oil flows from port A,, enters port R of the blade lift valve, pushes open check valve (4), and flows to port A, where it merges with the oil from the large pump.
D275A-2
1 O-89
Blade lever at HOLD, ripper lever at HOLD (oil being drained) In the condition in Item 1, if the hydraulic pressure in the circuit rises, the surface pressure (force pushing the demand valve to the left) on port L of demand valve (1) becomes greater than the combined force (force pushing the demand valve to the right) of the surface pressure bearing on port M and tension of spring (2), it moves the demand valve to the left, opens the circuits between ports A and E, and ports R and F. The oil from the large and small pumps is then relieved to ports E and F, and is drained from port G to the hydraulic tank. Therefore, both the large and small pumps are put in an unload condition.
From shuttle I/
ripper Lo valve 17MF02057
1O-90
D275A-2
3. Blade lever at RAISE (blade operating at high speed) When the blade lever is moved fully to the RAISE position, spool (5) moves to the left, and fully opens the circuits between ports B and C, ports C and H, and ports D and F. When this happens, the oil from the two pumps passes from ports A and B and enters port C. Some of the oil flows to the head end of cylinder (9), and the rest flows from port H, pushes shuttle valve (8) to the right and opens it, flows to port K, and enters ports N, 0, and P of shuttle valve (10). It then enters port Q of demand valve (1) and becomes the pilot pressure. At the same time, the oil from the pump passes through orifice a of demand valve (I), enters ports L and M, and becomes the pilot pressure. The oil at the bottom end of cylinder (9) flows from port D to port F, and returns from port G to the hydraulic tank. When the hydraulic pressure in the circuit rises in this way, spool (5) opens the circuit between ports B and C fully, so the resistance of the oil flowing from port B to port C is small, and there is little pressure difference generated between port B and port C. Therefore, no pressure difference is generated between port L and ports M and Q of the demand valve. The surface pressure acting on the left and right of the demand valve is equal, so the demand valve is moved to the right by the tension of spring (2). When this happens, the circuits between ports A and E, and ports R and F are closed, and all the oil from both the large and small pumps flows to the head end of the cylinder to increase the speed of movement of the cylinder. -
From shuttle valve inside ripper Lo valve
17MF02058
D275A-2
10-91
4.
Blade lever at RAISE (blade operating at low speed) When the blade lever is moved finely to the RAISE position, spool (5) moves slightly to the opens the circuit between left, and partially ports B and C, ports C and H, and ports D and F. the oil from the two When this happens, pumps passes from ports A and B, is throttled by spool (5), and enters port C. Some of the oil flows to the head end of cylinder (9), and the rest flows from port H, pushes shuttle valve (8) to the right and opens it, flows to port K, and enters ports N, 0, and P of shuttle valve (IO). It then enters port Q of demand valve (1) and becomes the pilot pressure. At the same time, the oil from the pump passes through orifice a of demand valve (I), enters ports L and M, and becomes the pilot pressure. The oil at the bottom end of cylinder (9) flows from port D to port F, and returns from port G tank. When the hydraulic to the hydraulic pressure in the circuit rises in this way the situation is different from in Item 3: spool (5) is throttling the circuit between ports B and C, so the flow of oil from port B to port C is restricted, and a pressure difference is generated port B and port C. The hydraulic between pressure in the circuit up to port B becomes higher. when the surface pressure acting Therefore, on port L of the demand valve (1) becomes greater than the combined force of the surface pressure acting on port M, the surface pressure acting on port Q and the tension of spring (2), the demand valve is moved to the left. When this happens, the circuits between ports A and E and ports R and F are opened, and the oil from both the large and small pumps is retank. This suppresses lieved to the hydraulic pressure at ports A the rise in the hydraulic and B, and the cylinder moves slowly. As explained in Items 3 and 4 above, the speed by of the cylinder is determined of movement the amount of opening of ports B and C correof the lever. If it is sponding to the movement wide open, the flow of oil beyond port C inpressure rises, and the creases, the hydraulic becomes faster. If it is opspeed of movement ened only slightly, the flow of oil beyond port so the oil flow is reduced, the C is throttled, low, and the becomes pressure hydraulic is slow. speed of movement In other words, the hydraulic pressure and oil so this proflow beyond port C is proportional, of the blade that folvides not only operation of the blade lever, lows the fine movements but reduces the pulling force (flow force) acting on spool (5), so the operating force of the spool does not increase.
1 O-92
ripper to Lo valve
N
10
17MF02059
D275A-2
5. Blade lever at RAISE (cylinder at stroke end) If cylinder (9) moves to the end of its stroke from the condition in Items 3 and 4, the hydraulic pressure in the whole circuit rises. Therefore, the hydraulic pressure beyond port C rises, and the oil entering the main relief valve (45) through shuttle valves (8) and (IO), that is, the oil at port P, pushes open poppet (13) and is relieved to port T. At this point, the circuit from port 0 to port P is throttled by orifice c, so the supply of oil to port P is delayed. As a result, the hydraulic pressure of pilot port Q of demand valve (1) drops, and the demand valve moves to the left. When this happens, the circuit between ports A and E and ports R and F are opened, and the oil from the two pumps is relieved to prevent the hydraulic pressure from rising any further. The hydraulic pressure at this point is 210 kg/ cm2.
t :...:.:.:.:.:.:.:.:.:.:.:.:.:!/
4% 1 il.,.,.,.,...
1'0
_
From small pump through ripper valve
*
From large pump
c
From shuttle valve inside ripper Lo valve
i 17MF02060
D275A-2
1o-93
6. Blade lever at LEFT TILT
a
4
To ripper
Hi valve IS
A’
17MF02061
l
When the ripper lever is moved to the LEFT TILT position, spool (16) moves down, opens the circuits of ports B, and C, and ports D, and F,, and closes the circuit of ports A, and A,. When this happens, the oil from the small pump flows from port A,, pushes open check valve (15), flows from port B,, and enters port C,. It flows to the bottom end of cylinder (17), and when the hydraulic pressure in the circuit rises, it extends the cylinder. At this point, the oil at the head end of the cylinder returns from port D, to port F,, and is drained from port E, to the hydraulic tank.
1o-94
The oil from the large pump enters port A of the blade lift valve, and actuates demand valve (1) in the same way as in Item 2. It is relieved from port A to E, and is drained to the hydraulic tank. When the blade tilt is operated, the circuit between ports A, and A, is closed, so the oil does not enter the ripper circuit, and it is impossible to operate the ripper. In other words, the blade tilt circuit is given priority over the ripper circuit.
D275A-2
Blade lever at LEFT TILT (cylinder at stroke end)
B
-
To ripper Hi valve
17MF02062
From the condition in Item 6, if cylinder (17) is moved to the end of its stroke, the hydraulic pressure in the whole circuit rises. When this happens, the oil from the small pump flows from port A,, and pushes open main relief valve poppet (14). It is then relieved to port E,, so the hydraulic pressure does not rise any further. The hydraulic pressure at this point is 210 kg/ cm*.
D275A-2
1 o-95
8. Ripper lever at TILT ON (ripper Lo valve, shuttle valve actuated)
/Hs ---22
17MF02063
.
When the ripper lever is moved to the TILT ON position, spool (19) moves up, opens the circuits between ports B, and D,, ports C, and E,, and ports A, and G,, and closes the circuit between ports A, and A,. When this happens, the oil from the small pump enters port A, and A,. Some of the oil pushes open check valve (18), flows from port B, into port D,, and the flows to port G, of the ripper Hi valve. The rest of the oil passes through the groove in spool (19), enters port G,, pushes shuttle valve (22) down fully, then flows from port H, to port S of shuttle valve (IO).
1 O-96
The oil entering port S passes through orifice b, and pushes piston (11). The reaction moves shuttle valve (IO) to the left, closes the circuit between ports N and 0, and opens the circuit between ports S and 0. The oil entering port 0 from port S then passes through orifice c, and enters ports P and 0. It becomes the pilot pressure of demand valve (I), and moves the demand valve to the right. When this happens, the circuit between ports A and E is closed, so the oil from the large pump is not drained to the hydraulic tank. The whole amount of the oil flows to port A, of the ripper Hi valve.
D275A-2
9. Ripper lever at TILT ON (ripper Hi valve actuated) As explained in Item 8, the oil from the large pump enters A, of the ripper Hi valve, pushes open check valves (23) and (35), flows to ports B, and B,, and stops. The oil from the small pump flows from port D4 of the ripper Lo valve and enters port G,. Some of the oil entering port G, passes through the passage inside valve (39), flows to port L,, and pushes shuttle valve (41) up fully. It then enters port N,, pushes spool (36) to the right, and becomes the pilot pressure. The rest of the oil is throttled by orifice f and enters port C,. Some of the oil entering port C, passes through the passage inside valve (39), flows to port J,, and pushes shuttle valve (44) down fully. It then enters port 0,, pushes spool (36) to the left, and becomes the pilot pressure. The rest of the oil flows from port C, to the bottom end of ripper tilt cylinder (45). When all the above hydraulic circuits are filled with oil, the hydraulic pressure starts to rise.
17MF02064
D275A-2
1o-97
.
From the condition previously explained, if the hydraulic pressure continues to rise,the oil at port G, is throttled by orifice f and enters port C,. Because of the resistance, the hydraulic pressure at port G, becomes higher than the pressure beyond port C,. Therefore, the hydraulic pressure at pilot port N, of spool (36) becomes higher than the hydraulic pressure at port 0,, so when this pressure difference becomes greater than the tension of spring (38), it pushes spool (36) out to the right. When this happens, the circuits between ports B, and C,, and ports D, and F, open, the oil from the large pump flows from port B, to port C,, enters the bottom end of ripper tilt cylinder (45), and merges with the oil from the small pump to extend the cylinder. Some of the oil at the head end of the cylinder returns from port D, to port F,, and is drained to the hydraulic tank. The rest of the oil flows from port D,, is throttled by orifice g of valve (42), and returns to port H,. It then flows from port C, of the ripper Lo valve, returns to port E,, and is drained to the hydraulic tank.
17MF02065
1 O-98
D275A-2
10. Ripper level at LOWER (ripper Lo valve, shuttle
valve actuated)
-
To
I
A2
ripper
Hi valve
/
A3
(A, port)
/
A4
17MF02066
0
When the ripper lever is moved to the LOWER position, spool (21) moves down, opens the circuits of ports B, and C,, ports D, and F,, and ports A, and G, and closes the circuit of ports A, and A,. When this happens, the oil from the small pump enters ports A,, A,, and A4. Some of the oil pushes open check valve (20), flows from port B, into port C,, and then flows to port H, of the ripper Hi valve. The rest of the oil passes through the groove in the spool, enters port G,, pushes shuttle valve (22) up fully, then flows from port H, to port S of shuttle valve (IO).
D275A-2
The oil entering port S passes through orifice b, and pushes piston (11). The reaction moves shuttle valve (IO) to the left, closes the circuit between ports N and 0, and opens the circuit between ports S and 0. The oil entering port 0 from port S then passes through orifice c, and enters ports P and 0. It becomes the pilot pressure of demand valve (I), and moves the demand valve to the right. When this happens, the circuit between ports A and E is closed, so the oil from the large pump is not drained to the hydraulic tank. The whole amount of the oil flows to port A, of the ripper Hi valve.
1o-99
11. Ripper lever at LOWER (ripper Hi valve actuated) As explained in Item 10, the oil from the large pump enters port A, of the ripper Hi valve, pushes open check valves (23) and (35), flows to ports B, and B,, and stops. The oil from the small pump flows from port C, of the ripper Lo valve and enters port H,. Some of the oil entering port H, passes through the passage inside valve (30), flows to port M,, and pushes shuttle valve (32) down fully. It then enters port 0,, pushes spool (24) to the left, and becomes the pilot pressure. The rest of the oil is throttled by orifice e and enters port D,. Some of the oil entering port D, passes through the passage inside valve (30), flows to port K,, and pushes shuttle valve (29) up fully. It then enters port N,, pushes spool (24) to the right, and becomes the pilot pressure. The rest of the oil flows from port D, to the bottom end of ripper lift cylinder (33). When all the above hydraulic circuits are filled with oil, the hydraulic pressure starts to rise.
From CS 17MF02067
10-100
D275A-2
.
From the condition previously explained, if the hydraulic pressure continues to rise, the oil at port H, is throttled by orifice e and enters port D,. Because of the resistance, the hydraulic pressure at port H, becomes higher than the pressure beyond port D,. Therefore, the hydraulic pressure at pilot port 0, of spool (24) becomes higher than the hydraulic pressure at port N,, so when this pressure difference becomes greater than the tension of spring (25), it pushes spool (24) out to the left. When this happens, the circuits between ports B, and D, and ports C, and E, open, the oil from the large pump flows from port 6, to port D,, enters the bottom end of ripper lift cylinder (33), and merges with the oil from the small pump to extend the cylinder. Some of the oil at the head end of the cylinder returns from port C, to port E,, and is drained to the hydraulic tank. The rest of the oil flows from port C,, is throttled by orifice d of valve (27), and returns to port G,. It then flows from port D, of the ripper Lo valve, returns to port E,, and is drained to the hydraulic tank.
17MF02068
D275A-2
10-101
12. Ripper lever at LOWER (cylinder at stroke end)
9
-1
I I
I I
17MF02069
D275A-2
a
From the condition in Items 10 and 11, if cylinder (33) is moved to the end of its stroke, the hydraulic pressure in the whole circuit rises. When this happens, in the same way as in Item 7, the oil from the small pump flows from port A, and pushes open main relief valve poppet (14). It is then relieved to port E,, so the hydraulic pressure does not rise any further. The hydraulic pressure at this point is 210 kg/ 2
oil passing through shuttle valves (22) and (IO), and flowing from ports S and 0 to port P also pushes open main relief valve poppet (13), and is relieved to port T. The circuit from port 0 to port P is throttled by orifice c, so the supply of oil to port P is delayed. As a result, the hydraulic pressure at pilot port 0 of demand valve (1) also drops, and the demand valve moves to the left. When this happens, the circuit between ports A and E opens, and the oil from the large pump is relieved, so the hydraulic pressure in the circuit of the large pump does not rise any further. The hydraulic pressure at this point is 210 kg/ cm2. When the hydraulic pressure in the whole circuit is set at 210 kg/cm2, the pressure difference on both sides of orifice e of valve (30), that is, the difference in pressure between ports H, and D,, disappears. The pilot pressure at port 0, that is pushing spool (24) to the left becomes the same pressure as the pressure at port N,. When this happens, spool (24) is returned to the right by the tension of spring (25) to a position where it is in balance with the tension of spring (26). At this point, the circuits between ports B, and D, and ports C, and E, are closed. The oil from the large pump goes as far as port B,, and stops. The oil at the head end of cylinder (33) flows from port C,, passes through orifice d of valve (27), and returns only to port
;Te’
G,.
D275A-2
10-103
PISTON VALVE (Blade lift and dual tilt cylinder)
STRUCTURE AND FUNCTION The piston valve is installed on the piston in the blade lift cylinder. When the piston reaches its stroke end, the valve releases the oil from the hydraulic pump to reduce the oil pressure being exerted on the piston. When the blade on a dual tilt dozer is tilted, the blade is subject to a tortional force owing to the uneven position of the pistons in the two cylinders; that is the piston one side is still moving while the piston on the other side has reached its stroke end. The piston valves are installed to prevent the tortional force from occurring. When one of the pistons reaches its stroke end, its piston valve opens to relieve the oil pressure. In addition, the piston valve relieves the shock which occurs when the piston comes into contact with the cylinder head or the bottom and serves to reduce the subsequent surge pressure in the cylinder by letting the oil escape from the cylinder before the piston reaches its stroke end.
OPERATION Piston valve CLOSED Pressurized oil from the hydraulic pump acts on piston (4) and piston valve (5). The piston valve is pushed in the direction of the arrow until piston valve seat (3) comes into snug contact with the tapered section, thereby, this causing the pressure in the cvlinder to rise of the and moving piston (4) in the direction arrow.
1. 2. 3. 4. 5.
\
17MF02070
Piston rod Cylinder Piston valve seat Piston Piston valve
\
/i
17MF02071
Piston valve OPEN Just before piston rod (1) reaches its stroke end, the front end of piston valve (5) comes into contact with the cylinder bottom (or the cylinder head) and is prevented from moving any further while piston (4) alone keeps on moving ahead. Then, the oil sealed within the piston valve on the cylinder head side will escape from piston valve seat (3) so that the oil pressure in the cylinder is prevented from rising. Strike 17MF02072
10-104
D275A-2
QUICK DROP VALVE
STRUCTURE The quick drop valve consists of valve body (I), spring (2), spool (3), check valve (4). The quick drop valve serves to increase the blade lowering speed and to reduce the occurrence of vacuum when the blade is lowering, thereby shortening the time lag before digging is started. The blade lowering speed,- which is generally determined by the pump discharge, can be made faster with the quick drop valve. 1. Valve body 2. Spring 3. Check valve
4. Spool
OPERATION 1. Start of lowering When the blade lever is operated to LOWER, the oil from the control valve enters the cylinder bottom through port A and pushes the piston. In the mean time, the oil in the cylinder head is pushed out into the piston, enters valve port B, and flows into the tank.
2. While lowering Pressurized oil from the cylinder head flows into port C through port B. At this time, the oil flow is restricted by an orifice provided along the way, causing a differential pressure before and after the orifice. When the differential pressure becomes greater than the force of spring (2), it compresses the spring and moves spool (3) and valve (4) to the right. With the spool and the valve have moved, part of the oil flowing from the cylinder head to the tank enters the passage to the cylinder bottom together with the oil from the control valve. Thus, the blade lowering speed increases in accordance with the amount of oil that flows to the bottom of the cylinder and reduces the formation of vacuum at the bottom of the cylin-
17MF02073
I75F209
der. 175F210
D275A-2
10-105
CYLINDER
STAY
17MF02074
1. 2. 3. 4. 5.
1 O-l 06
Yoke Oil seal Bushing Bushing Air bleeding plug
D275A-2
SEMI
U-DOZER
A-A
1. 2. 3. 4. 5.
Cutting edge Arm End bit Straight frame Trunnion
lo-108
6. Arm 7. Blade 8. Brace 9. Blade tilt cylinder 10. Blade lift cylinder
17MF02075
OUTLINE l The dozing attachment can be broadly divided into the blade and the hydraulic control which operates the blade. the diagram shows the semi U-dozer. The table shows the dimensions and specifications of the semi U-dozer.
D275A-2
D-D
B-B
F-F
E-E
G-G
J-J
K-K
H-H
M-M
L-L
17MF02076
OPERATION l The blade is moved by hydraulic cylinders. l RAISE: The left and. right lift cylinders retract and raise the frame and blade together. l LOWER: The left and right lift cylinders extend and lower the blade to the ground. . LEFTTILT: The tilt cylinder extends and lowers the left side of the blade to the ground. l RIGHT TILT: The tilt cylinder retracts and lowers the right side of the blade to the ground.
D275A-2
l
Table of comparisons Unit: mm Semi U-dozer Distance between left and right frame
3636
Length of frame
I
3775
Width of blade
I
4300
Height of blade
1910
Max. blade raise
1505
Max. blade lower
I
660
Max. blade tilt
I
1025
10-109
VARIABLE
MULTIPLE
SHANK
RIPPER
A-A
C-C
D-D
17MFOi077
10-l 10 0
OUTLINE l The ripping attachment can be broadly divided into the ripper and the hydraulic control which operates the shank. The diagram shows the variable multiple shank ripper. The table shows the dimensions and specifications of the variable multiple shank ripper.
OPERATION l The shank is moved bv hvdraulic cvlinders. The left and’right . RAISE: lift cylinders retract and raise the beam and shank together. . LOWER: The left and right lift cylinders extend and lower the beam and shank together to the ground. . TILT ON: The left and right tilt cylinders extend and move the shank forward. . TILT BACK: The left and right tilt cylinders retract and move the shank to the rearward.
Table of comparisons
l
Unit: Multiple Length of beam
I
No. of shanks 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Tilt cylinder Lift cylinder Beam Shank Protector Point Arm Pin Bushing Pin
D275A-2
shank ripper 2495 3
Shank pitch (with 3 shanks installed)
1130
Shank pitch (with 2 shanks installed)
2260
Ripping
)
depth
mm
I
2-stage selection possible
10-l11
8 f 6
-.
_ Section
A-A
Section
C-C
Section
B-B
P-
9
10
Section
D-D
__.-
Detail
P F197UR034A
10-112 0
OUTLINE l The ripping attachment can be broadly divided into the ripper and the hydraulic control which operates the shank. The diagram shows the variable giant ripper. The table shows the dimensions and specifications of the variable giant ripper.
OPERATION l The shank is moved by hydraulic cylinders. . RAISE: The left and right lift cylinders retract and raise the beam and shank together. The left and right lift cylinders ex. LOWER: tend and lower the beam and shank together to the ground. l TILT ON: The left and right tilt cylinders extend and move the shank forward. . TILT BACK: The left and right tilt cylinders retract and move the shank to the rearward.
Table of comparisons
l
Unit: mm \ Length of beam No. of shanks 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Tilt cylinder Lift cylinder Beam Shank Protector Point Arm Pin Bushing Pin
Ripping depth Max. ripping depth Max. raise
1
I I
I I
I
Giant ripper 1252 1 3-stage selection oossible 1300 870
10-112-l 0
123456789
, / / I
II
I
J 198F1113
1. 2. 3. 4. 5. 6. 7. 8. 9.
Plug Spring Spring retainer Valve body Spool Spring retainer Spring Push pin Solenoid assembly
A: B: C: D.
To pin-puller cylinder head From power train pump To pin-puller cylinder bottom To steering case
1 o-1 12-2 0
OUTLINE l
The pin-puller solenoid valve is in the circuit between the pin-puller cylinder and the power train pump passing through the steering control valve. When the pin-puller switch in the operator’s compartment is operated, it switches the oil from the power train pump and acts on the pin-puller cylinder to operate the shank mounting pin for the ripper shank. Solenoid assembly (9) is deactivated when pushed in and excited when pulled out.
OPERATION 1. Pin-puller switch at PUSH IN position When the pin puller switch is turned to the PUSH IN position, no current flows to solenoid (9) and it is deactivated. When this happens, spool (5) opens ports A and B and ports C and D, and the oil from the power train pump flows from port A to port B and enters the bottom of pin-puller cylinder (IO). The oil entering the bottom end of the cylinder increases the hydraulic pressure in the circuit and extends the cylinder. Shank mounting pin (11) is pushed into shank (13).
From power
train pump
Switch at PUSH IN position
198FO2028
2. Pin-puller switch at PULL OUT position When the pin-puller switch is turned to the PULL OUT position, current flows to solenoid (9) and it is excited. When this happens, the solenoid pushes out push pin (8), and spool (5) moves to the left in the direction of the arrow. Ports A and B and ports C and D close, and ports A and C and ports B and D open. The oil from the power train pump flows from port A to port C and enters the head of pin-puller cylinder (IO). The oil entering the head end of the cylinder increases the hydraulic pressure in the circuit and retracts the cylinder. Shank mounting pin (I 1) is pulled out of shank (13).
From power train pump
10. 11. 12. 13.
Pin-puller cylinder Shank mounting pin Beam Shank
Switch at PULL OUT position
198FO2029
1 o-1 12-3 0
CAB ELECTRICAL
CIRCUIT DIAGRAM
Serial No. : lOOOl-10127
R.H. door wiper
Front wiper
Rear wiper
Cigarette
Caution
lighter
lamp
Lock-up indication lamp
connection
Front and Rear window washer
Car
stereo
oc&o r
P
R.H. and L.H. window washer
198FO2034-2
10-118-4 @
Serial No. : 10128 and up
H /xd’bor
wiper
( ./ ! R. H door
P.
ont
II
r
I amp
Alarm L/C L/C
indi indi
cat cat
ear
r
IIll
wiDer
wiper
wiper
CN399
( 1 i
lamp
i
rette ter
1
F
0281330~ 02BOQQ1
(12V for
LR LB LA
power radio)
83 0 0
source Car
M
Front. wind
LY
rear washe
iI 2
CNMI
stereo
Converter
Z
r
M
10-118-5 8
ELECTRICAL CIRCUIT DIAGRAM
AIR CONDITIONER
Serial No. : 10001 - 10127
Control panel
I
Air-conditioner
Starting switch
switch
Pressure switch
85
CN 108
CN351
CN12 CN381
7L
Air conditioner compressor
Floor frame
Thermostat Blower motor
Air-conditioner
Blower resistor
relay
17MF02080
Serial No. : 10128 and up
Control Panel Blower
motor
switch
Air-conditioner
switch
S tart
ina
switch
Pressure
switch
conditioner ComIpressor
I
Floor
OOOQQQO~
frame
1,“IP,P,P,!::
1Ch365
Air
conditioner
unit
8°K
0
L-Y
M
Blower
Air
conditioner
relay
motor
Blower
resistor
Thermostat
-
SAD01517
10-118-7 @
EVMS
(ELECTRONIC
VEHICLE MONITORING
Monitor
SYSTEM)
panel
I
Sensor
signal
/
Buzzer signal
Buzzer
Caution
lamp
Battery F19702046
OUTLINE The vehicle monitoring system monitors varil ous conditions of the vehicle by means of sensors provided throughout the vehicle. It proand incesses the information immediately, forms the operator of the condition by making a display on the panel. There are two major kinds of panel display. 1. The monitor assembly, which gives a warning when any fault is monitored on the vehicle. 2. The gauge assembly and service meters, which constantly indicate the condition of the vehicle. (Engine water temperature, torque converter oil temperature and fuel level.)
D275A-2
l
l
l
The vehicle monitoring system consists of a monitor panel, sensors, warning lamps, warning buzzers, and the power source. The monitor panel, and sensors are connected by wiring harnesses. The power is supplied from the battery to the monitor panel. As soon as any trouble occurs, the monitor and warning lamps start flashing and the warning buzzer sounds to protect the vehicle.
10-119
67
8
9 10
F19802003
1. 2. 3. 4. 5. 6. 7.
Engine oil level Radiator water level Fuel level Torque converter oil temperature Engine water temperature Battery charge Engine oil pressure
OUTLINE l The monitor panel consists of the monitor portion that gives out warning when any abnormality occurs in the machine, and the gauge portion and service meter that always indicate the condition of the machine. The monitor and gauge portions each have microcomputers that process the signals from each sensor and display the results. A liquid crystal display is used. For details of the items displayed on the monitor and gauge portion, see the table on the next page. OPERATION 1. Power switched on (starting switch ON) 1) All items on the gauge and monitor light up for 3 seconds. 2) The warning lamps light up for 2 seconds and the alarm buzzer sounds for 1 second.
1 o-1 20
8. Radiator water level 9. Engine water temperature 10. Torque converter oil temperature 11. Hydraulic oil temperature 12. Preheat 13. Service meter indicator 14. Service meter
2. CHECK items 1) After lighting up as explained in Section 1, if there is any abnormality in any CHECK item, that item flashes. 2) The CHECK items go out when the engine is started. (The rise in the engine oil pressure is used to judge if the engine is running or not, or if the voltage from the alternator is more than 1OV.) CAUTION The caution items are checked from the time the engine is started until the time the engine is stopped. If there is any abnormality, the item flashes, and the warning lamp also flashes. If any items in CAUTION 2 flashes, the alarm buzzer also sounds. The monitor and warning lamps flash in an ON-OFF cycle of approx. 0.8 sec. The flashing cycle of the monitor may change slightly if the ambient temperature is low (approx. -10°C or below), but this is not an abnormality.
D275A-2
Monitor Classification 0 displav
panel indications
4 P
Method of indication
Radiator water level
Below LOW level
Engine oil level
Below LOW level
Indicates when the starting switch is turned ON with the engine stopped. If normal, the lamps do not light up. If abnormal, the lamps flash.
Engine oil pressure
When sensor is abnormal or wiring harness is disconnected
If normal, the lamps do not light up. If abnormal, the lamps light up.
3attet-y charge level
Insufficient charge
Indicates when the starting switch is turned ON while the engine is running. If normal, the lamp does not light. If abnormal, the lamp flashes and the warning lamp flashes at the same time.
Engine oil pressure
Below 0.5 kg/cm2
3adiator water level
Below LOW level
!ngine water temperature
When the engine water temperature gauge indicates the red ranqe (108” C or hiaher)
Torque converter
When the torque converter oil temperature gauge indicates the red range (over 130°C)
iydraulic
ET
Range of indication
Indication items
rmbol
oil temperature
oil temperature
Over 108°C When the preheat switch of seat switch is at ON, the lamp lights .rp (80 sec.) and changes to light going out to indicate that the preheating s completed.
When preheating
‘reheating
Engine water temperature
Indicates when the starting switch s turned ON while the engine is running. If normal, the lamp does not light up. If abnormal, the lamp and the warning ‘amp flash and the warning buzzer sounds.
102°C Green White
94°C 83°C 70°C
Lights up in the applicable
range
Lights up in the applicable
range
Red Torque converter
oil temperature
Green
Green Fuel level
Red
D275A-2
FULL 617 517 417 3/7 Z/7 EMPTY
Service meter
Indicates between 9999 hours.
zero and
Service meter indicator
When the service meter is working
All light up below the applicable
Operates while the alternator charging Clock time: 1 :l
level
is
Flashes while the service meter is working
10-121
SUPPLEMENTARY l
CONTROLLER
Tne supplementary controller acts as a power source box to supply electrical power to the panel assembly, switch panel, lock-up controller, etc. The variations in voltage of the power supply for the machine (battery, alternator) is large, so this supplementary controller transforms the power to a stable voltage before supplying it to the panel. Even if there is over-voltage caused by a failure in the alternator or regulator, it is cut here to protect the monitor panel.
CN 162 (3 pin)
CN464
(4 pin)
197FO2076
SENSOR The signal from the sensor is input directly to the machine monitor panel. One end of contact type sensors is always connected to the chassis ground. When the contacts of all the sensors except the engine oil pressure sensor close, and the signal wire is connected to the chassis ground, the panel judges it to be the normal signal. When the contact of the engine oil pressure sensor is open, and the signal wire is separated from the chassis ground, the panel judges it to be the normal signal.
l
Sensor
Type of sensor Engine oil level Radiator
water
Hydraulic
level
oil temperature
Engine oil pressure Engine water Torque
temperature
converter
Fuel level
10-122
oil temperature
I
method
When abnormal
When normal
Contact
ON
OFF
Contact
ON
OFF
Contact
I
ON
I
OFF
Contact
OFF
ON
Resistance
-
-
Resistance
-
-
Resistance
-
-
D275A-1
I
Engine oil level sensor
A Structure of circuit
197FO2077
1. 2. 3. 4.
Radiator
Connector Bracket Float Switch
water
FUNCTION The sensor is installed to the L.H. side face of the oil pan. When the oil goes below the set level, the float goes down and turns the switch OFF. The monitor then flashes to warn of the abnormality.
l
level sensor
m I
2
Structure of circuit
i
2
1. Float 2. Sensor 3. Connector
D275A-2
561FO3177
FUNCTION The sensor is installed to the top of the radiator. When the coolant goes below the set level, the float goes down and turns the switch OFF. The monitor then flashes to warn of the abnormality.
l
lo-123
Hydraulic
oil temperature
sensor
Structure of circuit 198FO2047
1. 2. 3. 4.
FUNCTION The hydraulic oil temperature sensor is installed to the hydraulic pump inlet tube. It detects the temperature at switch (I), and when the temperature goes above the set temperature, the switch is turned OFF. The display appears on the monitor panel, the warning lamp flashes, and the alarm buzzer sounds.
Switch Case Wire Connector
l
Engine oil pressure sensor
1
2
3
4
5
6
cl 69
@ Structure of circuit
202FO5175
1. 2. 3. 4. 5. 6.
Plug Contact ring Contact Diaphragm Spring Terminal
1O-l 24
FUNCTION This sensor is installed to the engine cylinder block. The diaphragm detects the oil pressure, and when it drops below the standard pressure, the switch is turned ON, and the lamp lights up to warn of the abnormality.
D275A-1
Engine water temperature sensor Torque converter oil temperature sensor
w Structure
of circuit 198FO2046
1. Connector 2. Plug 3. Thermistor
D275A-2
FUNCTION These sensors are installed to the thermostat housing and torque converter outlet port tube. Any change in temperature is taken as a change in resistance of the thermistor. A signal is sent to the monitor panel and the temperature is displayed. When the panel display reaches a set point, the lamp flashes and the buzzer sounds to warn of the abnormality.
l
10-125
Fuel level sensor
Structure
of circuit
A-A 198FO2089
1. 2. 3. 4. 5. 6. 7.
Connector Float Arm Body Spring Contact Spacer
1 o-1 26
FUNCTION The fuel level sensor is installed to the side face of the fuel tank. The float moves up and down according to the fuel level. This movement of the float is transmitted by the arm and actuates a variable resistance. This sends a signal to the monitor panel to indicate the remaining fuel level. When the display on the monitor panel reaches a certain level, a warning lamp flashes.
l
D275A-2
PANEL SWITCH
OUTLINE l
The panel switch incorporates soft touch sheet switches for the headlights, rear lamps, working lamps, torque converter lock-up, APS, and the engine starting switch. When a switch is depressed, the red lamp will come on; when depressed once again, the lamp will go off. When the starting switch is turned off while any one of the sheet switches is ON, all the sheet switches will go OFF. They will not come on again when the starting switch is turned on (to prevent the bulbs from breaking).
197F127
RELAY BOX OUTLINE l
The relay box houses various relays which energize the lamps, torque converter lock-up and APS. The lamp come on or go off through the operation of the corresponding relay when the panel switch is operated. The relay box also houses the APS controller, fuses for protecting various electrical equipment, and the safety relay that protects the panel switch and relays from over-voltage from the power source (battery and alternator).
198FO2055
D275A-2
lo-127
RELAY BOX CIRCUIT Serial No.: 10001-10127
CN 362
CN361
197FO2085-1
lo-128 @
I,
:
P ‘1.
E
::
e
” 0. 6 I. 26
0. 76
0. 5
0.75 1.25
_ _
L
017M02
I-
-0
00
‘t
‘-++?
2. 0
1.25
0. 75
I
I
I
Ii i
I
!
017M02
l
An over-voltage protection circuit is built into the controller for the monitor power source. The output of this controller turns the safety relay inside the relay box ON, and supplies electrical power to the relay coil and panel switches. In other words, if any over voltage (approx. 34V) should occur in the power source circuit due to an abnormality in the battery or alternator, the output of the controller is cut and the safety relay is turned OFF to protect the relay coil and panel switches. At the same time, power source to the monitor panel is cut. (When this happens, the monitor panel goes out and the panel switches cannot be operated.) When the engine is started, the battery voltage drops, so the circuit does not pass through the controller. A circuit is formed directly from starting switch C to turn the safety relay ON.
Safety function
circuit drawing
r
Monitor panel power source
-
--
--
Relay box
I-T
I
I I
I
tw
+
--1 Pane'switch
Relay power source Lock-up
______
I I
Safety relay
24” output
Supplementary controller (monitor power source)
I 1GND
lA
~
I+
;;E&
y&
~
I
l
e:lp I km
Alternator
197fO2086
D275A-2
1O-l 29
OPERATION .
OF LAMP SYSTEM
The lamps are lighted up by operating the panel switch. A signal is then sent to the relay box, and the relay inside the relay box is actuated to supply electricity to the lamp. Panel switch
Example of head lamp system When the head lamp switch on the panel is l pressed, the contacts of the head lamp switch close, and are connected to the ground. Electricity flows from the battery through the safety relay and fuse to the head lamp relay coil to close the head lamp relay contacts. When this happens, the electricity from the battery passes through the fuse, enters the head lamp relay, and flows to the head lamp to light up the head lamp. At the same time, electricity also passes through diode D,, and flows to the monitor night lighting night lighting to light up and air conditioner flows in the these lamps also. The electricity same way when the rear lamp switch and working lamp switch on the panel are pressed. The lamps, then lights up the respective electricity night lighting. monitors, and air conditioner
Monitor panel (night lighting)
\..._,,*’
F19702047
Head lamp system circuit diagram Relay box
--1
Safety relay
r---
Panel switch
I
Head lamp relay (L.H. and R.H.)
Head lamp
The power for the monitor night lighting is supplied from R.H. head lamp relay
I I I
_ -
I
Monitor illumination (3
Rear lamp -1
ncr
Working lamp -1
L 10-130
D4 +.am
Air conditioner illumination
Diode
,
I __
__I
747 197FO2088
D275A-2
APS CONTROL SYSTEM Serial No. : 10001 - 10167
Engine From fuel injection pump Air intake manifold
Water temperature sensor
’ I I I
Monitor panel
1 Water manifold
y
I
I
Glow plug
Relay F19702048
APS SYSTEM
DIAGRAM
Fuel motor
1 Glow plug 2
Nozzle
Alternator CzGT
-__
nl7 J 197FO2090
1O-l 32 @
FUNCTION
APS start Flowoftime
APS stop
-
I
---------
Starting motor running
Glow plug preheating Starting switch Preheat switch (panel switch)
START (hand)
ON (hand)
I
OFF
OFF
OFF
Nozzle
OFF
ON
I
OFF
ON
I OFF
I OFF
I
ON
I
I
OFF
OFF
ON OFF
OFF (hand)
Min. 20°C
Light up
Preheat relay
Glow plug
I
Max. 20°C
Monitor panel display
Preheat back-up relav
ON
ON (hand)
I
APS water temp. sensor
Heater relay
_____-----------
Engine start Heat up the glow plug
OFF ON
OFF 197F134
sj
l
The APS functions to heat the air intake by burning the fuel in the intake manifold.
Z Z
The APS will operate in the following order When the engine cooling water temperature goes below 2o”C, the APS water temperature sensor contacts will close, thereby causing the signal line to connect to the machine body and causing the preheating relay to energize. Under the above condition, when the engine heat switch on the panel switch is depressed or when the starting switch is turned to HEAT, the large capacity heater relay to come ON, causing the current to flow to the glow plug to heat up the glow plug. The impressed voltage is lowered by a resistor to 18V to meat the rated voltage of the glow plug. The bimetal timer will operate while the glow plug is heating and the preheat (APS) pilot lamp will also light up. When the glow plug preheating time is up, the bimetal timer will come OFF and the pilot lamp will go OFF. This indicates that the glow plug is heated enough to operate the APS.
After the APS pilot lamp goes off, the APS controller is activated by turning the starting switch to START. The fuel injection nozzle in the intake manifold starts injecting fuel intermittently (IO times/set) through ON operation. After the engine is started, the fuel injection nozzle is operated by the alternator signal (so that the nozzle works only when the engine is running). When the engine water temperature rises above 2o”C, the APS water temperature sensor contacts open and the heater relay goes off, causing the glow plug to stop heating and the fuel injection nozzle to stop injection fuel. The preheat backup relay make use of the START signal to short both terminals of the resistor to supplement the voltage drop of the battery when the engine is started.
10-132-l 6%
Serial No. : 10168 and up
Panel
switch
Engine From fuel i,on Pump inject
1I Air
intake
manifold
I
Nozzle
I
:=
Seal portion:
to
Grease (G2-LI)
*
2)
Push the piston rod in to the end of its stroke. Tighten head assembly (10) with mounting bolts. m
Mounting bolt: 17MF02745
Quick drop valve (blade lift cylinder only) Assemble collar (6), valves (5) and (4), spacer (3), and spring (2), then fit O-ring and install block (1). Tube Fit O-ring and install tube.
I
30-230 0
l98FO2792
REMOVAL OF WORK EQUIPMENT ASSEMBLY
A
Stop the machine on a firm, level place, and lower the work equipment to the ground. securely under the Then put blocks 0 straight frame on the left and right.
1. Remove cap (1).
m j, Check the number and thickness shims (2), and keep in a safe place.
of the
2. Sling blade lift cylinder (3), start engine and retract piston rod fully, then fit cylinder lock plate to secure to guard. A Tie the rod with wire to prevent it from coming out. * Repeat Steps 1 to 2 to disconnect the cylinder on the other side from the blade.
175FO2577
Stop the engine and operate the control lever several times to release the pressure in the hydraulic remaining piping. Then loosen the oil filler cap slowly to release the pressure inside the hydraulic tank.
2 17MF02746
17MF02747
3. Remove right cover (4). 4. Disconnect hose (5). A Make match marks before disconnecting the hose. * Fit a blind plug to prevent dirt or dust from entering the piping. 5. Remove left and right trunnion caps (6).
6. Remove work equipment assembly (7). IfEt21 A Start engine and drive machine slowly in blade assembly reverse to disconnect from trunnion on track frame.
I98FO2808
30-231 0
INSTALLATION
l
Carry out installation removal.
OF WORK EQUIPMENT ASSEMBLY
in the reverse order to
Adjust so that play C of the spherical portion in the axial direction is within 0.5 mm, but can still rotate smoothly. Standard shim thickness: 4 mm
Adjust with a block @ so that the height and width of the left and right straight frames are dimensions A and B as shown below. Dimensions A: Approx. 2876 mm Dimensions B: Approx. 559 mm
198F1423
30-232 0
DISASSEMBLY
A
OF WORK EQUIPMENT ASSEMBLY
Insert 5 blocks 0 under the left and right straioht frames, the bottom of the blade, and the left and right arm mounts to set the dozer assembly securely in the position.
1. Sling tilt brace (I), and remove lock plate, then pull out pin (2). * If the pin is stiff, rotate brace (1) with lever (3) to adjust. 2. Remove lock plate, then remove tilt brace (1). &
Tilt brace:
pull out pin (4) and
I
150 kg
17MF02749
3. Raise right center brace (5) and left center brace (6), remove pins (7) and (8) and connection with straight frame, then remove. m
A *
8 z lz
Always prevent
put block @ under arm (9) from falling.
the arm to
There are shims at the spherical connection at the straight frame end, so check the number and thickness of the shims, and keep in a safe place. &
Center brace:
130 kg
4. Sling straight frame (IO), then connecting pin (11) and lift off. & *
Straight
frame:
17MF02749
4 remove
900 kg
Check the condition of the block and be careful to prevent the blade from falling over during the operation.
6
I
._ 10
\
5
17MF02750
\11 17MF02751
30-233 0
5. Raise blade (12) and tip blade over. 6. Raise right arm (13), remove connection of blade (12) and left arm (14), then remove. Raise left arm (14). then remove from blade (12). PI kg
Blade: 3550 kg
6 kg
Arm:
175 kg
A There are shims at both ends and at the center spherical connection, so check the number and thickness of the shims, and keep in a safe place.
I
li
17MF02752
17MF02753
8 z z
30-234 0
ASSEMBLY OF WORK EQUIPMENT ASSEMBLY
* There
* .
are shims at all connections, so assemble the same number and thickness of shims as was disassembled, and adjust all dimensions. Coat the connecting pins with grease when installing. Carry out assembly in the reverse order to disassembly.
m
* * *
Adjust the shim at the spherical joint so that play of the spherical portion in the axial direction is within 1 mm, but can still rotate smoothly. Standard shim thickness: 4 mm If the arm does not match when connecting, shake the straight frame on the left or right to align.
1121 . Adjusting dimension C * Adjust so that the play of the spherical
*
portion in the axial direction is within 1 mm, but can still rotate smoothly. Standard shim thickness: 4 mm
C
C F15A01185
30-235 0
DISASSEMBLY
OF RIPPER ASSEMBLY
1. Set block 0, raise machine, and lower blade assembly to ground.
A
Lock brake pedal securely.
2. Sling shank (1) temporarily, operate pin-puller cylinder and pull out pin. (For giant ripper) 3. Start engine, raise ripper fully, then shank (1) gradually, and remove. & kg
Shank:
lower
350 kg
4. Set block 0 under arm and beam to support ripper assembly. 5. Sling lift cylinder assembly (2) temporarily, remove pin (3). * Start engine, retract piston rod fully, and lower to arm. 6. Sling tilt cylinder assembly (4) temporarily, remove pin (3). * Start engine, retract piston rod fully, and lower to arm. *
Operate the control levers several times to release the remaining pressure in the hydraulic piping.
7. Sling beam (6), then using forcing screws 0, remove left and right pins (7) and remove beam (6). Beam:
&
1750 kg
8. Disconnect hoses (8) and (9). 9. Sling tilt cylinder assembly remove pin (10) and lift off.
el kg
Tilt cylinder assembly:
IO. Sling lift cylinder assembly remove pin (11) and lift off. & kg
Lift cylinder assembly:
(4) temporarily, 190 kg (2) temporarily, 205 kg
11. Sling arm, then using forcing screws Q, remove left and right pins (12), and remove arm (13). & kg
30-236 0
Arm:
700 kg
2755
ASSEMBLY OF RIPPER ASSEMBLY
1. Insert block under the arm, and set arm (13) in mounting position, install left and right pins (12) and lock with lock plate.
_
assembly (2) in mounting 2. Set lift cylinder position, then install pin (11) and lock with lock plate. 3. Set tilt cylinder assembly (4) in mounting position, then install pin (10) and lock with lock plate. 4. Connect
hoses (9) and (8).
5. Insert block 0 under the beam, and set beam (6) in mounting position, install left and right pins (7) and lock with lock plate. assembly (4) temporarily, 6. Sling tilt cylinder start engine, extend piston rod and align pin hole, then install pin (5) and lock with lock plate.
8 Is z
7. Sling lift cylinder assembly (2) temporarily, start engine, extend piston rod and align pin hole, then install pin (3) and lock with lock plate. 8. Set block 0, raise machine, assemly to ground.
A
and lower
‘/
2
-
17MF02759
blade
Lock brake pedal securely.
9. Start engine, raise ripper assembly, and insert wire in hole of shank holder hook, then raise shank (1) gradually, align pin hole and install. 10. Raise blade, lower
machine
11. Bleed the air from hydraulic
from block 0. cylinder.
.
Bleeding air Bleed the air from cylinder. For details, see TESTING AND DADJUSTING. * Refill each connect pin with grease.
30-237 0
REMOVAL OF ROPS GUARD
1. Sling ROPS gvard (I), and remove mounting bolts, then remove ROPS guard. )#II &
ROPS guard:
INSTALLATION GUARD l
Carry out installation removal.
550 kg
OF ROPS
in the reverse order to
m m
30-238 0
Guard mounting bolt: 135 f
15 kgm
762
REMOVAL OF OPERATOR’S CAB ASSEMBLY
A
Disconnect the cable from the negative terminal of the battery.
(-)
1. Remove ROPS guard. For details, see REMOVAL OF ROPS GUARD. 2. Remove left and right covers (I), then remove rubber mat (2). 3. Remove left, right, and rear panel covers (3). 4. Disconnect central wiring connectors (4). * After disconnecting the connectors, fit caps to prevent dirt or dust from getting in. 5. Disconnect panel (6).
cable
(5), then
remove
heater
6. Disconnect 4 wiper hoses (vinyl hoses) (7). j, When disconnecting the hoses, mark them with tags to indicate the position where they are connected. m 7. Remove 14 cab mounting bolts, raise slowly, then remove operator’s cab assembly (8). m
el kg
Operator’s cab assembly:
500 kg
17MF02767
30-239 0
l
Carry out installation removal.
in the reverse order to
*
They vinyl hoses can be distinguished by their color, so connect the hose with the same color as the joint.
*
Install the cab assembly as follows. 1) Set mounting dimension a of adjusting joints installed at points A - G in the diagram to 10 - 12 mm. 2) Set cab assembly on floor frame, screw bolts 3 - 4 threads into points A - N in the diagram to check that the bolts can be tightened. 3) Tighten bolts H - N in the diagram. * When tightening the bolts, check that adjusting joints A - G in the diagram are not in contact with the surface of the floor frame. 4) Screw in adjusting joints A - G in the diagram until they contact the surface of the floor frame, then tighten the mounting bolts.
After installing the ROPS cab, check that the instruments and other equipment work normally.
30-240 0
I
17MFO2769
17MF02770
REMOVAL OF FLOOR FRAME ASSEMBLY
1. Remove operator’s cab assembly. For details, see REMOVAL OF OPERATOR’S CAB ASSEMBLY. 2. Remove covers (I), (2), and (3), floor plate (4) and step cover (5).
4
\
17MF02
3. Remove wiring clamp, and disconnect wiring connectors (6), (7), (8), (9), (IO), (11) and (12). * After disconnecting the connectors, fit caps to prevent water, dirt or dust from getting in. 4. Disconnect ground connection (13).
8
17MF02772
E ‘0
5. Remove cover (14). 6. Loosen top and bottom locknuts, rotate joint, and disconnect 4 transmission and steering control rods (15). 1111 7. Remove 2 mounting cable lock bracket.
bolts
(16)
of control
17MF02774
17MF02775
8. Disconnect heater hoses (17). * After disconnecting the hoses, fit caps to prevent dirt or dust from getting in. 9. Disconnect cooler hose (18). * When disconnecting the hoses, mark them with tags to indicate the position where they are connected. 10. Disconnect fuel control rod (19). m * After disconnecting the rod, tie it with wire to the floor to hold it in position.
30-241 0
11. Disconnect brake rod (20).
m
12. Disconnect control rod (21) of work equipment. m * After disconnecting the rod, tie it with wire to the floor to hold it in position.
17MF02777
13.
Remove 4 front and rear mounting bolts, then raise floor frame assembly (22) slowly and remove. j, Be careful not to damage the control cables, rods, and wiring when removing the assembly. PI kg
Floor frame assembly:
650 kg
17iFOi779
INSTALLATION OF FLOOR FRAME ASSEMBLY l
Carry out installation removal.
w
in the reverse order to
Locknut: 0.8 + 0.2 kgm
* After connecting
* *
Insert the stopper for the yoke connecting pin securely. After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting fuel control linkage.
m Bend the cotter securely.
30-242 0
After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting brake pedal linkage.
*
Insert the stopper for the yoke connecting pin securely. After connecting the rod, adjust it correctly. For details, see TESTING AND ADJUSTING, Adjusting ripper, blade control linkage.
m
the cables, adjust them
correctly. For details, see TESTING AND ADJUSTING, Adjusting speed lever linkage, and Adjusting steering clutch linkage.
m
*
*
w
Floor frame mounting bolt: 135 f
15 kgm
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 ................... ..... l Main relief valve and shuttle valve Blade tilt control and ripper low valve ..... Ripper high valve ....................... Hydraulic cylinder ...................... l Blade lift cylinder .................... l Blade tilt cylinder .................... ................... l Ripper lift cylinder l Ripper tilt cylinder ................... l Dual tilt cylinder ..................... l Pin puller cylinder .................... Quick drop valve ....................... Cylinder stay ........................... Semi U-dozer .......................... l Cutting edge and end bit .............. Ripper ................................. ......... l Variable multiple shank ripper l Variable giant ripper ..................
40- 2 40- 4 40- 6 40- 8 40-I 0 40-I 2 40-14 40-16 40-17 40-18 40-20 40-22 40-24 40-26 40-28 40-30 40-32 40-34 40-36 40-38 40-43 40-44 40-45 40-46 40-47 40-48 40-48 40-48 40-48 40-49 40-50 40-50 40-51 40-52 40-54 40-56 40-58 40-58 40-60
40-l 0
ENGINE MOUNT
94.5 + 10.5 kgm
94.5 f 10.5 kgm
B-B 17MF02101 A-A Unit: mm
No.
Check item
Criteria
Remedy
Tolerance I
Clearance
between
bracket and cushion
Standard size
70
2
40-2
Shaft
Hole
f0.018 -0.012
+0.046 0
Standard clearance
Clearance limit
-0.018 0.058
0.1
Standard size
Repair limit
108
106
Replace
Free height of mounting rubber
D275A-2
m
94.5/fl0.5 kgm
94.5f10.5 kgm
5
j
3
2.
p
,
1 P
i!
u
J
A-A 17MF02102
40-4
D275A-2
DAMPER AND UNIVERSAL JOINT
28.5 f 3
km
17MF02103 Unit: mm No.
Remedy
Criteria
Check item
Tolerance 1
I
2
Clearance between and cover
Clearance
flywheel housing
between flywheel and damper
Standard size
Standard clearance
Clearance limit
Shaft
Hole
647.7
-0.024 -0.105
+0.080 0
0.024 0.185
0.2
546
-0.022 -0.092
f0.110 0
0.022 0.202
0.25
I Standard 3
Outside diameter of coupling
4
Outside diameter of output shaft
5
Dimension
-
40-6
size
Repair limit
of oil seal contact surface
of oil seal contact surface
between
bearing and holder
0 ’ “-0.087
109.9
0 l lo-0.035
109.9
46 + 0.1
47.7
w
11.25fl.25kgm
w
11.25~1.25kgm
7
w
5.5f0.5kgm
8
6.75 f 0.75 kgm
11.25+
11.25+1.25kgm
6.75fl25kgm
1 .I5 f 0.15 kgm
1.25 kgm
6.75 f 0.75 kgm
-5
17MF02104
40-8
D275A-2
Unit: mm
NO
1
2 3
Check item
Outside diameter of coupling
Remedy
Criteria Standard size
Tolerance
120
I
0 -0.100
inside diameter of retainer
of seal ring contact surface
II
+0.040 0
Inside diameter of sleeve
of seal ring contact surface
170
110 I
PTO drive gear and
5
Backlash between driven gear
PTO drive gear and
6
Wear of seal ring of stator shaft
-
170.5
I
+0.035 0
110.5 I
Clearance limit
0.250 -
0.420
-
0.204 -
0.516
-
Width: Height:
Repair limit Width: Height:
4.45 6.00
5.0 Overall thickness
8
Stator clutch
15.0
Thickness of disc
5.0
Thickness of plate
5.0
Overall thickness
I
Stator clutch spring
D275A-2
4.5
4.5
I
4.5
I
15.0
Replace
13.8
I
13.9
I
Standard size
9
4.00 5.40
4.5
5.0 7
High chrome painting repair or replace
,
Standard size
-
119.8
I
Standard clearance Backlash between driven gear
4
Repair limit
I
of oil seal contact surface
I
Repair limit
Free length
Installation length
Installation load
Free length
Installation load
35
27
8.7 kg
32.8
7.4 kg
40-9
TORQUE CONVERTER VALVE
6 __-__
8
9
17MF02105
40-10
D275A-2
Unit: mm
No.
Remedy
Criteria
Check item I
I
r
I
1
Tolerance Clearance between main relief valve and valve body
1 I
Standard size I
I
Standard clearance
Hole
Shaft
I
I
Clearance limit I
40
-0.035 -0.045
f0.016 0
0.035 0.061
0.08
2
Clearance between torque converter relief valve and valve body
40
-0.035 -0.045
f0.016 0
0.035 0.061
0.08
3
Clearance between stator clutch modulating valve and valve body
25
-0.035 -0.045
f0.013 0
0.035 0.058
0.08
4
Clearance between lock-up clutch modulating valve and valve body
25
-0.035 -0.045
f0.013 0
0.035 0.058
0.08
5
Clearance between lock-up selector valve and valve body
40
-0.035 -0.045
f0.016 0
0.035 0.061
0.08
Repair limit
Standard size
6
Main relief valve spring
Free length 120.3
Installation length
Installation load
102.0
144.57 kg
Free length 116.7
Replace
Installation load 137.3 kg
7
Torque converter relief valve spring
116.92
90.8
56.16 kg
I 13.41
53.35 kg
8
Stator clutch modulating valve spring
103.5
92.7
20.10 kg
100.4
19.10 kg
Lock-up clutch modulating valve spring (outer)
141.4
88.7
16.18 kg
137.16
15.37 kg
1o
Lock-up clutch modulating valve spring (inner)
80.5
80.5
II
Lock-up selector valve spring
g
I
I 10.07
100.0
-
3.0 kg
78.09 106.8
2.85 kg
40-11
TRANSMISSION
17MF02106
40-12
D275A-2
Unit: mm
No.
Criteria
Check item
I
No. I clutch spring
(12 PCS.)
2
No. 2 clutch spring
(12 PCS.)
3
No. 3 and 4 clutch spring
(I 2 PCS.)
4
No. 5 clutch spring
5
Overall thickness of No. 1 clutch
60.3 1
91.0
1
22.3 kg
71.9
7.75
(5 PCS.)
1
7.40
Standard
Remedy
16.6 kg
65.8
1
1
85.5
137.2 kg
size
19.0 kg
-
14.1 kg 116.6 kg
Tolerance
Repair limit
45.5
* 0.3
42.9
6
Overall thickness of No. 2 clutch
41.2
* 0.3
38.6
7
Overall thickness of No. 3 clutch
23
* 0.2
21.4
8
Overall thickness of No. 4 clutch
27.3
f 0.2
25.7
9
Overall thickness of No. 5 clutch
41
* 0.3
38.4
4.8
* 0.1
4.3
10
Thickness of discs of No. I -
II
Thickness of discs of No. 5 clutch
5.0
* 0.1
4.5
12
Thickness of plates of No. I -
4.3
+ 0.1
3.9
13
Thickness of plates of No. 5 clutch
14
Wear of seal ring of input shaft
4 clutches
Replace
4 clutches
-
I5
16
4.0
I
f
I
Width:
3.0
0.1
Width:
Thickness:
3.1
Thickness:
Width:
4.5
Width:
Thickness:
5.8
Thickness:
Wear of seal ring of No. 5 clutch
Width:
5.0
Width:
Thickness:
6.0
Thickness:
-0.01 -0.03 * 0.15
Standard clearance 17
0.13 18
Backlash between and rina__ aear
19 20
-
No. 1 planetary
gear
Width:
2.7
Thickness:
2.9
Width:
4.1
Thickness:
5.6
Width:
4.5
Thickness:
5.8
Clearance
Backlash between No. I and 2 sun gears and planetary gears I
0.13 -
0.40
-
Backlash between No. 2,3 and 4 planetary gears and ring gear
0.14 -
0.40
-
Backlash between olanetarv aears
0.13 -
0.37
-
No. 3 and 4 sun gears and
limit
-
0.40
I
-0.01 -0.03 f 0.10 -0.01 -0.03 + 0:15
Wear of seal ring of output shaft
3.6
I
40-13
TRANSMISSION
CONTROL VALVE
17MF02107
D275A-2
Unit: mm
Clearance
10
between
modulating
Reducing valve spring
D275A-2
valve
68.0
55.5
26.7 kg
66.0
25.37 kg
40-15
POWER TRAIN AND LUBRICATING
PUMP
BAL100+140
11.5f
1.0 kgm_
11.5f
1.0 kgm
BALI 40
BALI00
I97F2008
Unit: mm No.
Check item
Criteria Model
1
Side clearance
Remedy
Standard Clearance
Clearance
BALl 00
0.04 -
0.10
0.13
BAL 140
0.07 -
0.12
0.15
0.145
0.20
limit
BAL 100 2
Clearance between inside diameter of plain bearing and outside diameter of gear shaft
0.060 -
Replace
BAL 140 Model 3
Pin insertion depth
Standard
size
Tolerance
Repair limit
BAL 100 14
0 -0.5
-
BAL 140 4
Rotation torque of spline shaft
0.6 kgm
@pm)
Pressure (kg/cm’)
Standard discharge (a/min)
Repair limit discharge (a/min)
BAL 100
2200
30
200
185
BAL 140
2200
30
280
258
Model
Revolution
Discharge Oil: Class-CD SAE 1OW Temperature:
40-16
45 -
50°C
D275A-2
TRANSFER AND BEVEL PINION
.25 f 3.25 kgm
f 0.75 kgm
I
/ m
18+2kgm
m
\ 18*2kgm
m
18f2kgm 17MF02108
Unit: No.
I
Check item
Criteria
I Standard
Backlash
of transfer
Standard Thickness of collar and bearing
Clearance
clearance
between
transfer
Standard
D275A-2
shim thickness
of bearing
Repair
size
gear
cage
Remedy
Adjustment or replace
0.75
0.61
limit Replace
14.6
15
3
limit
gears 0.22 -
2
I
mm
I
2.0
Adjustment
40-17 @
BEVEL GEAR SHAFT, STEERING CLUTCH AND STEERING BRAKE
n
___-_---------___ ----
j--v /-t __ Ir-4d
I
m
1;.5+1
kgm
m
25+15kgm
w
V 18+2kgm 17MF02109
40-18
D275A-2
Unit: mm No
Check item
Criteria Standard
Remedy Repair limit
size
-
Thickness of brake and clutch plate 2.9
2.6
Tolerance
Repair limit
within 0.3
0.4
Replace
1
Correct or replace
Strain of brake and clutch plate
Standard
size
Repair limit Replace
Thickness of brake and clutch disc 4.5
4.2
Tolerance
Repair limit
within 0.3
0.4
2 Correct or replace
Strain of brake and clutch disc
3
Standard
Overall thickness of brake plates and discs
4
Overall thickness of clutch plates and discs
5
Backlash between and brake hub
brake and clutch discs,
53.8
59.2
57.7
clearance
0.4 -
0.7
0.3 -
0.4 0.8
6
Backlash between bevel pinion
7
Clearance between seal ring groove of piston and seal ring
0.5 -
8
Clearance between seal ring groove of cage and seal ring
0.5 -0.8
-
Repair limit
56.3
Standard
bevel gear and
size
Clearance
Replace limit
1.0 Adjustment or replace
0.75
I
0.8 0.8
I
I
I
Tolerance 9
Inside diameter of seal ring contact surface of cage
Standard size 275
-
Shaft
Hole
Standard clearance
- 0.110 - 0.191
+ 0.081 0
0.110 0.272
10
Inside diameter of seal ring contact surface of brake piston
230
- 0.100 - 0.172
+ 0.072 0
0.100 0.244
11
Inside diameter of seal ring contact surface of clutch piston
220
- 0.100 - 0.172
+ 0.072 0
0.100 0.244
Standard 12
Brake belleville spring
13
Clutch belleville spring
Clearance limit
Replace
Repair limit
size
Free length
Installation length
Installation load
Free length
Installation load
16.5
10.4
3.530 kg
15.9
3.550 kg
16.5
10.6
3.500 kg
15.9
3.330 kg
Tolerance 14
Interference between reamer bolt
bevel gear and
Standard size 14
-
Shaft
Hole
+ 0.019 + 0.001
+ 0.027 0
Standard interference -
0.026 0.019
Interference limit 0.02
15
Face runout of back of bevel gear
Repair limit: 0.05 (measure
16
Preload of tapered roller bearing of lever gear shaft
Standard rotating torque: 0.4 - 0.5 kgm (2.2 - 2.8 kg at tip of bevel gear teeth with bevel pinion and bevel gear not meshed)
17
Standard
shim thickness of bearing cage
D275A-2
after installing to bevel gear shaft)
2.0
~~~~c&e Adjustment
Adjust shim
40-19
STEERING CONTROL VALVE
197F161
40-20 D275A-2
Unit: mm
No
Remedy
Criteria
Check item
Tolerance 1
Standard size
Clearance between brake and clutch valves, and valve body
Standard clearance
Clearance limit
+0.013 0
0.020 0.043
0.06
Hole
24.0
-0.020 -0.030
clutch shaft and
I
24.0
-0.020 -0.030
+0.013 0
0.020 0.043
0.06
between
brake shaft and guide
I
22.0
-0.034 -0.043
+0.013 0
0.034 0.056
0.08
between
brake shaft and guide
I
20.5
-0.034 -0.043
f0.013 0
0.034 0.056
0.08
Clearance between and piston
brake and clutch valve,
I
9.0
-0.030 -0.040
f0.015 0
0.030 0.055
0.08
Clearance between valve body
check valve and
I
20.0
-0.020 -0.041
f0.052 0
0.020 0.093
0.11
2
Clearance between valve body
3
Clearance
4
Clearance
5 6
Replace
I 7
_ Shaft
Clutch modulating
spring
Standard
size
I
Free length
Installation length
Installation load
76.0
49.0
14.7
Repair limit Free length
Installation load
kg
72.0
14.0 kg
kg
40.0
6.9 kg
8
Clutch valve return spring
41.9
32.0
7.3
9
Clutch shaft return spring
15.5
15.5
-
10
Brake modulating
50.0
42.0
6.5
kg
47.5
6.2 kg
11
Brake valve return spring
50.2
37.0
18.0
kg
47.5
17.1 kg
12
Check valve spring
38.5
30.0
0.34 kg
34.5
0.3 kg
14.0
-
spring
-
40-21
N 80flOkgm
\
w 28.5 f 3 kgm
135?15kgm
8/
,_.l~YmYrjI bm
120?10kgm
w
56+6
kgm
w
cgx53
28.5 do3 kgm
15.5 * 2.5 kgm
17MF02110
40-22
D275A-2
Unit: mm
No
Standard Backlash between No. 1 gear
Remedy
Criteria
Check item clearance
I
No. 1 pinion and
2
Backlash between planetarv aear
sun gear and
3
Backlash between ring gear
planetary
4
Outside diameter of oil seal contact surface of No. 1 pinion
gear and
Clearance
I
1.5
0.28 -
0.93
0.22 -
0.81
1.5
0.25 -
0.90
1.5
Standard
limit
I
I
Repair limit
size
Replace 95.0
94.9
16.5
15.0
5
Height of cover and ball
Tolerance
6
Clearance carrier
between
Standard size
pinion shaft and
85
7
Clearance in axial direction of No. 1 pinion bearing
8
Press-fitting force of rubber bushing
9
Press-fitting force of sun gear
I
Shaft
Hole
-0.036 -0.058
-0.024 -0.059
0 -
0.1 (Standard
Standard clearance
Clearance limit
-0.023 0.034
0.1
shim thickness:
Max. 13.5 ton
2) Adjustment
Max. 10 ton
40-23
MAIN FRAME
A
A
6
A-A
8
D-D 17MF02111
40-24
D275A-2
Unit: mm No.
Remedy
Criteria
Check item
Tolerance Standard size
’ Clearance between radiator guard mounting pin and bushing
Standard clearance
Clearance limit
Shaft
Hole
80
-0.030 -0.076 -0.030
f0.479 f0.380 f0.329
0.410 0.555 0.343 -
80
-0.076
f0.313
0.405
1.5
Press-fitting force of ripper beam mount bushing
110
-0.036 -0.090
+0.164 +0.062
0.098 0.254
1.5
Clearance between ripper cylinder mounting pin and bushing
90
-0.036 -0.090
+0.170 f0.073
0.1090.260
1.5
Clearance mounting
between
radiator guard
pin and bushing
Press-fitting force of radiator guard mount bushing
6.2 -
14.1 ton
Press-fitting force of radiator guard mount bushing
10.2 -
23.2 ton
Clearance between pin and bushina
7.1 -
14.0 ton
5.9 -
11.7 ton
1.0 Replace
Adjustment ripper beam mounting I
I
8
Press-fitting force of ripper cylinder mount bushina
D275A-2
40-25
TRACK FRAME
-
_--.------
-%-
_--
15.5 f 2.5 kgm
m
A-A
i.
-.-.-.--_.e B-B 17MF02112A
40-26 0
Unit: mm No.
Check item Standard
1
Clearance
between
Remedy
Criteria size
Repair limit Adjustment
idler yoke and guide 0 - 0.5
3
40-27
7
6
2
1
56f6kgm
m
135f15kgm
25 f 3.25 kgm
159.5 & 17.5 kgm B-B A-A F17MO2006
40-28
D275A-2
Unit: mm
No -
1
Remedy
Criteria
Check item
Recoil spring
Tolerance
2
Clearance between outside end and inside end of outside cylinder bushing
3
Clearance bushing
between
adjustment
cylinder and
4
Clearance between inside cylinder and adjustment cylinder
Standard size
Standard clearance
Clearance limit
f0.317 f0.060
0.115 0.545
0.8
-0.100 -0.350
f0.054 0
0.100 0.404
-0.15 -0.35
f0.1 0
0.15 0.45
Shaft
Hole
340
-0.055 -0.228
110
50
Item
2.0
Repair limit
I
7 (in length of 3000 mm)
Bend 5
Replace
Correct or replace
Deformation of track frame (outside cylinder) Torsion
3 (in length of 300 mm)
Dents (bent plate)
10
6
Press-fitting force of outside cylinder bushing
7
Press-fitting force of inside cylinder bushing
8
Dimension
-
between
front pilot and nut
4.3 4.5 -
9.8 ton 23.3 ton
Adjustment
4.0
40-29
IDLER
1 3 21 zt 5 kgm
9’
I
L- -
--
___._-I 17MF02114
40-30
D275A-2
Unit: mm No.
Criteria
Check item Standard
Remedy Repair limit
size
Outside diameter section
of idler protrusion
2
Outside diameter
of idler tread face
3
Width of idler protrusion section
4
Width of idler tread face
5
Overall width of idler
266
-
6
Width of collar of shaft
242
-
7
Clearance
between
872
-
830
805
124
107
71
Rebuild or replace
79.5
Clearance limit
shaft and bushing 155
-
-0.350 -0.413
+0.220 -0.120
1
0.230 0.633
1.5
Standard interference
IInterference limit
Replace bushing
I
Tolerance
8
Interference
between
shaft and seal guard
Standard size 95
-
Shaft
Hole
+0.046 0
-0.150 -0.200
0.150 0.246
Replace
I Standard 9
clearance
Clearance
limit
Free play of shaft in the axial direction 0.47 -
D275A-2
0.83
1.5
40-31
TRACK ROLLER
k
8,_
6
,9
4
5
11
,7
12 /
/
1
w
21 f5
kgm
17MF02115
40-32
D275A-2
Unit: mm
No.
Criteria
Check item Standard
1
Outside diameter
size
Remedy Repair limit
of flange (outside) -
291 2
1 Outside
diameter
of flange (inside)
I
3
4
Outside diameter tread face
1 Overall
284
II
width of track roller
I
-
1
of track roller
255
219
327
I
1
-
5
Width track roller tread face (single flange)
74
83
6
Width of track roller tread face (double flange)
74
93
7
Width of flange (single flange)
8
Width of flange (double flange outside)
9
Width of flange (double flange inside)
10
Width of collar of shaft
) 11
12
13
Clearance
Interference seal guard
between
27.5
I I
I
24
I
Standard size
18.5 14
I
276
I
18.5
I
27.5
-
I
ki
Rebuild or replace
:ta::;;
Cly$ce
shaft and bushing
between
130
-0.350 -0.413
10.260 +0.010
0.360 0.673
Replace bushing
1.5
Tolerance shaft and
Standard size
70 Standard
Shaft
Hole
-0.150 -0.200
f0.046 0
clearance
Standard interference
Interference limit
0.150 0.246
-
Clearance
Replace
limit
Free play of shaft in the axial direction 0.49 -
0.86
I
1.5
40-33
CARRIER ROLLER
4
-
-
i-i
6
-li__li-
_
3
3
--
-1 I
_-
-
-21
*5kgm
/
‘\“\
I
17MF02116
40-34
D275A-2
Unit: mm No
Check item
Criteria Standard
1
Outside diameter
size
I
of flange 242 of carrier roller
Remedy Repair limit
I
I
-
I
2
Outside diameter tread face
3
Width of carrier roller tread face
68
I
79
I
4
Width of flange
23
I
12
I
210
Rebuild or replace
185
Tolerance 5
Clearance
between
shaft and support
Standard size
Shaft 0 -0.2
86
6
Interference seal guard
between
shaft and
Standard size
+0.245 +0.185
Standard
clearance
Free play of roller in the axial direction 0.01 -
D275A-2
f0.350 0
Standard clearance
0.22
Clearance limit
Replace bushing
o-
I
0.550
~~.::tar:de
90
7
Hole
lnteyferynce
f0.035 0
I I
0.150 0.245 Clearance 0.3
Replace
limit
I I
40-35
TRACK (LUBRICATED TRACK LINK)
6
m
1st tightening: 80 * 8 kgm 2nd tightening: 120’ f IO”
5
w
1
I
1st tightening: 50 5 5 kgm 2nd tightening: 180” f IO”
197F169
40-36 0
D275A-2
Unit: NC
Criteria
Check item Standard
1
I Repair limit
size
mm
Remedy
Turn or replace
Link pitch 260.6
2
Height of grouser
3
Link height
4
Outside diameter
88
30
161
143
Lug weld, repair by build-up welding, or replace Repair by build-up welding or replace
84 (Normal loading) 86.5 (Hard loading)
92.5
of bushing
-
5
Interference
between
link and bushing
I
I
I
Turn or replace
Standard size
92 6
Interference
between
57
link and pin
+0.30 +0.20
-0.21 -0.28
0.41 0.58
0.25
I
7
Clearance
D275A-2
between
links
ri
Replace
40-37 0
SUSPENSION Serial No.:
(l/3)
10001 -10127
_..e
[Pivot shaft L.H. side]
___.._----------
,2---\
“1
[Pivot shaft R.H. side]
17MF02117
40-38 @
D275A-2
Rear
*
Front
C-C
17MF02118
Unit: mm
No.
Check item
Criteria
Remedy
Tolerance Interference and seal
1
2
between
thrust washer
Interference and seal
between
thrust washer
I
Interference and seal
between
pivot shaft
I 4
Interference and seal
between
side pin bushing
c
Interference
between
side pin boss
Interference
between
side pin boss
3
Standard size
,~
Standard interference
Interference limit
Shaft
Hole
210
f0213 f0.098
-0.180 -0.226
0.278 0.439
140
+0.140 +0.100
-0.061 -0.124
0.161 0.264
194
+0.096 +0.050
-0.115 -0.187
0.165 0.283
-
100
+0.035 0
-0.104 -0.171
0.104 0.206
-
180
f0.250 f0.130
0 -0.070
0.130 0.320
-
140
0 -0.018
-0.068 -0.098
0.050 0.098
-
Standard clearance
Clearance limit
Tolerance 7
8
Clearance between
I
g
I 1o
11
12
I
pivot shaft and bushing
Standard size
Shaft
Hole
155
-0.145 -0.208
f0.132 f0.059
0.204 0.340
1 .o
190
-0.170 -0.242
f0.144 f0.059
0.229 0.386
1 .o
Clearance between center shaft and equalizer bar bushing
105
-0.036 -0.090
f0.274 f0.180
0.216 0.364
1.o
Clearance between center shaft
105
-0.036 -0.090
f0.274 +0.178
0.214 0.364
1.o
Clearance between
pivot shaft and bushing
bolster bushing and
Press-fitting force of equalizer Press-fitting
bar bushing
3.3 -
23 ton
force of bolster bushing ;I
Adjustment
Press-fitting force of side pin bushing
D275A-2
40-39
Serial
No. : 10128 and up
9
3
a
: A-A [Pivot shaft L.H. side]
7-.-
L.f
[Pivot shaft R.H. side]
17MF02117
40-39-l @
D275A-2
SBDO1524
Unit: mm
No.
Remedy
Criteria
Check item
Tolerance between
Interference and seal
1
between
Interference Interference
3
thrust washer
thrust washer
between
pivot shaft
ti between
I
Interference and seal
side pin bushing
Interference and seal
between
side pin boss
I 6
interference between and bushing
side pin boss
7
Clearance
4
5
Shaft
Hole
210
f0.213 f0.098
-0.180 -0.226
140
f0.140 f0.100
-0.061 -0.124
f0.096
-0.115 -0.187
194
f0.050
I
Standard interference
Interference limit
0.278 0.439
-
0.161 0.264
I
0.165 0.283
-
Replace
between
between
pivot shaft and bushing
pivot shaft and bushing
8
Clearance
g
Clearance between center shaft and equalizer bar bushing bolster bushing and
,o
Clearance between center shaft
11
Press-fitting
force of equalizer
12
Press-fitting
13
Press-fitting
D275A-2
Standard size
Standard size
/=I
Standard clearance
limit
Hole
155
-0.145 -0.208
f0.132 +0.059
0.204 0.340
1 .o
190
-0.170 -0.242
f0.144 +0.059
0229 0.386
1 .o
105
-0.036 -0.090
+0.274 f0.180
0.216 0.364
1 .o
105
-0.036 -0.090
f0.274 +0.178
0.214 0.364
1 .o
32.4 - 225.6
kN 13.3 - 23 ton)
force of bolster bushing
19.6 - 127.5
kN {2 - 13 ton)
force of side pin bushing
68.6 - 133.4
kN {7 - 13.6 ton)
bar bushing
1 Clearance
Shaft
Adjustment
40-39-2 @
SUSPENSION
(2/3)
F-F
17MF02119
Unit: mm
No
Criteria
Check item
Tolerance 1
Interference
between
_
Standard size
rod and rod bushing
90
2
Clearance between rod pin and bolster hole and crossbar hole
I
Shaft
Hole
0 -0.015
-0.024 -0.059
Standard interference 0.009 0.059
Tolerance Standard
Standard
Clearance limit
Replace
0.5 Clearance
between
4
Clearance
at spherical face of rod pin
5
Press-fitting force of rod bushing
3
-
40-40
rod and rod bushing
I
I I
60
80
-0.030 -0.060
I
+0.046 0
0.7 -
0.030 0.106
0.5
0.08 0.15
0.5
4.4 ton
~ D275A-2
SUSPENSION
(313)
Small cushion Small cushion
Large cushion /
Large cushion \
\
17MF02120
---_ t3-l
+
I I
Z-Z
B’
_
_
+
e
Under cover
(When chassis is contacting ground)
f
z-z
z-z
(When chassis is floating)
(When chassis is floating)
17MF02121 Unit: mm
No
Criteria
Check item Standard value
Remedy Repair limit
Total of stepped difference at bottom face of equalizer bar and bottom face of under-bar
Replace cushion 2.0 f 2.0
8.0
Procedure for measurement Measure the stepped difference at two places (e and f) in front of and behind the center (portion P) of the equalizer bar center pin. When the chassis is floating, operate the blade tilt to make the equalizer bar horizontal. With the chassis in contact with the ground, raise the blade and ripper, and measure stepped difference A at the bottom face of the equalizer bar and the bottom face of the under-bar. (At points e and f) With the chassis floating (the chassis lifted off the ground by using the blade and ripper), measure stepped difference 6 or B’ at the bottom face of the equalizer bar and the bottom face of the under-bar. (At points e and f) * For machines not equipped with blade and ripper, jack up the chassis at the front and rear. Calculate the movement of the equalizer bar as follows: l With the chassis floating, when the bottom face of the equalizer bar is in the +direction from the bottom face of the under-bar:A -6 l With the chassis floating, when the bottom face of the equalizer bar is in the -direction from the bottom face of the under-bar:A +B * If the movement of the equalizer bar is more than 8.0 mm, check for damage to the cushion (large), (small), and replace the cushion. (The same applies if the value is more than 8.0 mm at either point e or point f.)
D275A-2
40-41
HYDRAULIC PUMP SAR (3) 100 + SAR (2) 50
/ m
.
28.5 f 3.5 kgm
m
28.5 f 3.5 kgm
I= SAR (3) 100
SAR (2) 50 17MF02122
Unit: mm No
Check item
Criteria Model
1
2
Side clearance
limit
Clearance
0.13 -
0.18
SAR (2) 50
0.10 -
0.15
SAR (3) 100
0.06 -
0.149
0.20
SAR (2) 50
0.06 -
0.149
0.20
0.22
I
0.19
I
Pin insertion depth
Standard 14
SAR (3) 100
I
0 - 0.5
I I
-
2.4 kgm
Pressure (kg/cmz)
Standard discharge (n/min)
Repair limit discharge (n/mm)
SAR (3) 100
2500
210
231
214
SAR (2) 50
2500
210
112
102
Revolution
I
I
(rpm)
Model
Replace
-
0 - 0.5 1.4 -
I
I
Repair limit
Tolerance
14
Rotation torque of spline shaft
Oil: Class-CD SAE 1OW 45 - 55°C Temperature:
size
Remedy
I
Clearance between inside diameter of plain bearing and outside diameter of gear shaft
SAR (2) 50 4
clearance
Standard
SAR (3) 100
Model 3
I
I
-
I
40-43 Q
BLADE LIFT CONTROL VALVE
m
kgm
19fl B-B
A-A
m
3.5 _+0.5 kgm
D-D
E-E
F-F
197FO2120
40-44
D275A-2
MAIN
RELIEF VALVE AND SHUTTLE VALVE
k 1 .O kgm
7.0 f
197Fl74
/ m
7.0 f 1 .O kgm Unit:
No
Check item
Criteria Standard
1
Spool return spring
size
Remedy Repair limit
Free size
Installation length
Installation load
55.6
38.0
6.0
kg
52.1
4.8
Free length
Installation load kg
2
Detent spring
20.5
17.0
3.7
kg
19.8
2.96 kg
3
Check valve spring
75.7
43.5
1.0
kg
69.3
0.8
kg
4
Check valve spring
32.7
24.5
4.5
kg
31 .o
3.6
kg
5
Suction valve spring
75.9
38.5
1.16 kg
69.4
0.93 kg
6
Demand spool spring
121.4
99.0
36.0
kg
114.7
28.8
kg
7
Main relief valve spring
41 .I
32.6
26.4
kg
39.4
21.1
kg
8
Shuttle valve spring
42.7
22.0
0.83 kg
38.6
Height of main relief pressure adjustment screw
mm
Replace
0.66 kg
8 (one turn of the screw will charge the pressure by: 24.9 kg/cm’)
‘.
D275A-2
40-45
BLADE TILT CONTROL AND RIPPER LOW VALVE
m
3.5 f 0.5 kgm
197F175
0.5 kgm Unit: mm
No.
Criteria
Check item
I
Remedy
Standard size
Spool return spring
40-46
D275A-2
RIPPER HIGH VALVE 135
2
1 3.5
+ 0.5
52.5 * 2.5
kgm
,3
197FI
76
Unit: : mm
No.
Criteria
Check item
Remedy
Standard size Spool return spring
Replace
BLADE LIFT CYLINDER
\ w
11.25+1.25kgm 17MF02123
BLADE TILT CYLINDER
w
50;5kgm
m
11.;5f
1.25 kgm 17MF02124
RIPPER LIFT CYLINDER
w
11.25kl.25
kgm
I
17MF02125
40-48
D275A-2
17MF02126
Unit: mm No
1
Clearance between piston rod and bushing
70
f0.200 0
1.o
Ripper lift
90
+0.207 +0.120
1 .o
Ripper tilt
90
+0.207 f0.120
1 .o
Blade lift
95
Blade tilt
70
+0.174 +0.100
2.0
Ripper lift
90
+0.207 f0.120
1 .o
Blade tilt
3
4
5
Clearance between piston rod connecting pin and bushing
Clearance between trunnion bushing and cylinder stay
Clearance between cylinder bottom connecting pin and bushing
Ripper tilt
6
Remedy
Criteria
Check item
Standard shim thickness between too of oiston rod and cao
Blade lift
II
-0.170 -0.250
1 .o
90 I
I
I
f0.207 f0.120 4.0
1 .o I
I
I I
Adjustment
DUAL TILT CYLINDER
m
50+-5kgm
11.25f1.25
kgm
17MF02127
PIN PULLER CYLINDER
m
45 f 4.5 kgm \
17MF02128
Unit: mm
No.
1
Check item
Clearance between and bushing
piston rod
Criteria
Dual tilt Pin puller
2
Clearance between piston rod connecting pin and bushing
3
Clearance between pin and spherical face of piston rod
4
Clearance between cylinder bottom connecting pin and bushing
5
Clearance between cylinder bottom support shaft and boss
40-50
D275A-2
QUICK DROP VALVE
17MF02129
Unit: mm
No
Remedy
Criteria
Check item
Tolerance 1
Clearance between valve body
plunger and
Standard size
38.0
Shaft
Hole
-0.011 -0.016
+0.010 0
Standard
2
Valve spring
D275A-2
Standard clearance
Clearance limit
0.011 0.026 Replace Repair limit
size
Free length
Installation length
Installation load
Free length
Installation load
75.2
55.9
13.9 kg
67.7
12.5 kg
40-5 1
CYLINDER STAY
3
1
2
17MF02130
Unit: mm Remedy
Criteria
Check item
No.
Tolerance
1
Clearance between and bushing
cylinder yoke
2
Clearance between and bushing
cylinder yoke
3
Clearance between and bushing
lift cylinder trunnion
40-52
Standard size
Standard clearance
Clearance limit
f0.063 0
0.085 0.211
0.5
-0.072 -0.126
+0.054 0
0.072 0.180
0.5
-0.120 -0.207
+0.035 0
0.120 0.242
0.5
Shaft
Hole
140
-0.085 -0.148
105 95
Replace
D275A-2
SEMI
U-DOZER
li'
B-B
‘7
c-c
5
A-A
14 \
F-F
E-E
G-G
5
J-J H-H
40-54
K-K 17MF02131
D275A-2
17MF02132
Unit: mm
ce between
D275A-2
joint and bracket
40-55
CUlTING
EDGE AND END BIT
w
152.5 + 16.5 kgm
T
1
L
m
152.5 + 16.5 kgm
_-------------------------------
i
1
197Fl8l-I
Unit: mm No.
Check item
Criteria Standard
1
size
Remedy Repair limit
Height of end bit outside 415
300 Replace
2
Width of end bit
662
500
3
Height of end bit inside
330
260
4
Height of cutting edge
330
260 (215 after turned)
Replace or turn
D275A-2
VARIABLE MULTIPLE SHANK RIPPER
6
---
5
A-A
C-C
40-58 0
B-B
D-D
Unit: mm No.
Remedy
Criteria
Check item
Tolerance
1
Clearance between and bushing
Standard size
bracket and arm pin,
Clearance between and bushing
beam and arm pin,
3
Clearance between pin and bushing
cylinder connecting
Hole
Clearance limit
1 I”
-0.036 -0.090
+0456 f0.369
0.405 0.546
~c “=
110
-0.036 -0.090
+0.456 +0.369
0.405 0.546
1.5
90
-0.036 -0.090
f0.207 f0.120
0.156 0.207
1.5
..n
2
Shaft
Standard clearance
Replace Standard 4
Dimension
of shank mounting
Tolerance
size
pin 80
* 0.3
Standard 5
Wear of point
6
Wear of protector
D275A-2
Repair limit
I
131
Repair limit
size
I
106
I
VARIABLE
GIANT RIPPER
-..-
” -.-
A-A
B-B
P-
tL_l
c-c
D-D
-..-
il
40-60 0
Detail P
Unit: mm
No.
Remedy
Criteria
Check item
Tolerance Clearance between and bushing
1
Standard size
bracket and arm pin,
2
Clearance between and bushing
beam and arm pin,
3
Clearance between pin and bushing
cylinder connecting
Standard clearance
Clearance limit
+ 0456 + 0.369
0.405 0.546
1.5
- 0.036 - 0.090
+ 0.456 + 0.369
0.405 0.546
1.5
- 0.036 - 0.090
+ 0.207 + 0.120
0.156 0.207
1.5
Shaft
Hole
110
0.036 - 0.090
110 90
I
I 4
I
Standard
Dimension
of shank mounting
I
I 5
6
f 0.3
80
I
I
1 Wear
I
I
pin
Reolace Repair limit
Tolerance
size
Standard
size
I I
Repair limit
I
of point
Wear of protector
131
106
40-61 0
Komatsu America international Company 440 North Fairwav Drive I Vernon Hills, IL 66061-8112 U.S.A. Attn: Technical Publications Fax No. (847) 970-4186
PROPOSAL
1
FOR MANUAL
REVlslON
FOR INTERNAL USE ONLY -- No. PMR 2
NAME OF COMPANY:
:
PHONE NO:
: S
DEPARTMENT:
E R
NAME:
MANUAL NAME: MANUAL NO: MACHINE MODEL: S/N IF APPLICABLE: PAGE NO:
PROBLEM:
Attach photo or sketch. If more space is needed, use another sheet.
1 FOR INTERNAL USE ONLY CORRECTIVE ACTION:
PFMRl 081696
LOCATION:
DATE:
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