D275A-2 up Shop Manual

February 28, 2018 | Author: Hugo Valdes Barrios | Category: Transmission (Mechanics), Clutch, Gear, Screw, Manufactured Goods
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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

.---------$----f--,

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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