D275A-2MACHINE D275A-2 MODEL SERIAL NUMBER 10001 and up.This shop manual area. Please Materials may contain attachments and optional without equipment notice. that are not available you may require. in your

KOMRdbU

consult

your local Komatsu are subject

distributor to change

for those items

and specifications mounts

.

D275A-2

the S6D170-1

and S6D170-2

engine. and 6D170-2 Series Engine Shop Manual.

For details

of the engine,

see the 6D170-1

Series

@ 1996 KOMAl%U All Rights Reserved02-96(03)02951

oo1@

CONTENTSNo. of page

01

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*..................

01-l

10 STRUCTURE AND FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10-l

20

TESTING AND ADJUSTING

. . . . . . . ..-...............................

20-l

30

DISASSEMBLY AND ASSEMBLY . . . . . . . . . ..*................n......

30-l

40

MAINTENANCE

STANDARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40-l

00-2 0

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00-2-3 @

SAFETY

SAFETY

NOTICE

SAFETYSAFETY NOTICESAFETYand repair

IMPORTANTProper service

NOTICEis extremely important for safe machine operation. The

service and repair techniques are both effective designed To prevent manual. by Komatsu

recommended

by Komatsu

and described

in this manual

and safe. Some of these techniques for the specific purpose.

require the use of tools specially

injury to workers,

the symbol a

is used to mark safety precautions should always be followed

in this care-

The cautions

accompanying situation

these symbols

fully. If any dangerous take the necessary

arises or may possibly arise, first consider

safety, and

actions to deal with the situation.

GENERAL Mistakes carefully

PRECAUTIONS in operation are extremely and dangerous. Manual

6. Decide

a place

in the

repair

workshop correct

to keep

keep tools and removed Read the Operation Maintenance the machine. or repairs, Always

parts. Always

the tools and parts in their

places.

keep the work area clean and make for smok-

BEFORE operating

sure that there is no dirt or oil on the floor. Smoke only in the areas provided ing. Never smoke while working.

1. ,Before carrying which 2. When

out any greasing

read all the precautions

given on the decals

are fixed to the machine. carrying out any operation, always PREPARATIONS 7. Before FOR WORK oil or making or tracks any repairs, and the

wear safety shoes and helmet. loose work clothes, missing. . Always . Always wear wear

Do not wear adding park the machine on hard, level ground, to prevent

or clothes with buttons hitting grind-

safety glasses when safety glasses etc. always carry when

block the wheels machine 8. Before ground. equipment

parts with a hammer. ing parts with a grinder, 3. If welding trained, ways

from moving. starting If this work, lower blade, ripper, to the the

bucket or any other work equipment have a out the work, alhand is not possible,

repairs are needed, experienced carrying welding welder gloves,

insert

safety pin or use blocks to prevent the work from falling. In addition, be sure to lock all the control ing signs on them. 9. When disassembling or assembling, blocks, jacks support or stands levers and hang warn-

work. When wear

out welding

apron,

shield, cap and other clothes suited for welding work. 4. When ating carrying procedure out any operation always before starting. with two Always in-

the

machine

with

or more workers,

agree on the operbefore starting any work,

before starting IO. Remove

work.

all mud and oil from the steps or use the handrails, ladders or

form your fellow workers step of the operation. hang UNDER in the operators 5. Keep all tools

other places used to get on and off the machine. Always steps when Never jump impossible getting on or off the machine. If it is or ladders

Before starting

REPAIR signs on the controls compartment. and learn

on or off the machine. to use the handrails,

in good condition

the correct way to use them.

steps, use a stand to provide

safe footing.

00-3

SAFETY

SAFETY

NOTICE

PRECAUTIONS 11 When or

DURING

WORK

19. Be sure to assemble original places. Replace any damaged . When installing

all parts again

in their

removing

the oil filler cap, drain plug pressure measuring plugs, to prevent the oil from compofirst the from

parts with new parts. be sure is beby contact

hydraulic out.

hoses and wires,

loosen them spurting Before remove circuit. 12. The when Wait water

slowly

that they will not be damaged ing operated. 20. When sure installing that they high pressure are

with other parts when the machine or removing completely or air circuits,

disconnecting the pressure

nents of the oil, water

hoses, make Damaged careparts

not twisted.

tubes are dangerous, and oil in the circuits are hot ful when circuits. installing Also, the engine is stopped, so be careful to cool before

so be extremely connecting

tubes for high pressure

check that installed.

not to get burned. for the oil and water out any work carrying circuits. 13. Before starting work, remove the leads from the battery. the negative Always remove first. use a hoist the lead from (-1 terminal on the oil or water

are correctly

21. When assembling use the specified installing or parts which high speed,

or installing tightening

parts, always torques. When

protective vibrate

parts such as guards, violently correctly. or rotate at careful to check

be particularly

that they are installed 22. When fingers fingers 23. When which has aligning caught

14. When raising heavy components, or crane.

two holes, never insert your Be careful not to get your in a hole. hydraulic pressure, check assem-

or hand.

Check that the wire rope, chains and hooks are free from damage. Always ample Install places. slowly use lifting equipment capacity. the lifting to prevent equipment at the correct and operate from hitany Use a hoist or crane

measuring

that the measuring

tool is correctly

bled before taking any measurements. 24. Take care when When removing removing the track, or installing the track the sepa-

the component

tracks of track-type rates suddenly,

machines.

ting any other

part. Do not work with

part still raised by the hoist or crane. 15. When ternal spring, removing pressure always covers which or under leave two are under infrom a

so never let anyone stand at

either end of the track.

pressure

bolts in position release the pres-

on opposite

sides. Slowly

sure, then slowly loosen the bolts to remove. 16. When wiring 17. When removing components, be careful fires. not

to break

or damage

the wiring.

Damaged

may cause electrical removing piping,

stop the fuel or oil Fuel or oil

from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. on the floor even start fires. 18. As a general mum parts. rule, do not use gasoline when washing to can cause you to slip, or can

wash parts. In particular, of gasoline

use only the minielectrical

00-4

FOREWORD

GENERAL

FOREWORDGENERALThis shop serviceman manual has been prepared as an aid to improve the quality of repairs by giving the an accurate understanding of the product and by showing the contents him the correct way to perform of this manual and use it to full

repairs and make judgements. effect at every opportunity.

Make sure you understand

This shop manual service workshop. chapters are further

mainly

contains

the necessary

technical

information is divided

for operations

performed chapters;

in a these

For ease of understanding, divided

the manual

into the following

into the each main group of components.

STRUCTURE

AND

FUNCTION the structure and function of each component. It serves not only to give for troubleshooting. of the structure, but also serves as reference material

This section explains an understanding TESTING This

AND ADJUSTING section explains checks to be made before and after performing repairs, as well as to be made at completion charts correlating of the checks and repairs. to Causes are also included in this section.

adjustments

Troubleshooting DISASSEMBLY This section assembling MAINTENANCE

Problems

AND ASSEMBLY explains the order to be followed when removing, installing, disassembling or each component, STANDARD standards when inspecting disassembled parts. as well as precautions to be taken for these operations.

This section gives the judgement

NOTICEThe time with specifications and the without latest date. contained any advance in this notice. shop manual are subject to change given in the at any book Use the specifications

00-5

FOREWORD

HOW TO READ THE SHOP MANUAL

HOW TO READ THE SHOP MANUALVOLUMES Shop manuals are issued as a guide to carrying out repairs, They are divided as follows: Chassis volume: Issued for every machine model Engine volume: Issued for each engine series Electrical volume: Attachments volume: Each issued as one volume to cover all models REVISED When pages. EDITION MARK is revised, an edition bottom mark of the

a manual

(@@@....)

is recorded

on the

REVISIONS Revised pages are shown in the LIST OF REVISED PAGES next to the CONTENTS page.

I

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

SYMBOLS So that the shop manual can be of ample practical use, important safety and quality portions are marked with the following symbols.

Any additions, amendments or other changes will be sent to KOMATSU distributors. Get the most up-to-date information before you start any work. 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): 10 -3 Item number (IO. Structure and Function) Consecutive page number for each item. Example 12 - 5 Unit number (I. Engine) Item number (2. Testing and Adjusting) Consecutive page number for each item. 2 (Engine volume):

Symbol

Item

Remarks Special safety precautions are necessary when performing the work.I I

A*

Safety

/ 1Caution

Special technical precautions or other precautions for preserving standards are necessary when performing the work. Weight of parts of systems. Caution necessary when selecting hoisting wire, or when working posture is important, etc. Places that require special attention for the tightening torque during assembly. Places to be coated with adhesives and lubricants, etc. Places where oil, water or fuel must be added, and the capacity. Places where oil or water quan-

Weight

Tightening w torque

&

Coat

Oil, water

3. Additional

pages:

Additional

pages are indiafter the

& b & Drain

cated by a hyphen page number. Example:1 o-4

(-1 and number

File as in the example.

m;yob,

dd:,ii,,d. and

112-203

I

10-4-I > 1O-4-2 IO-5

Added

pages -1:

~~~~~I~ 12-204

00-6

FOREWORD

HOISTING

INSTRUCTIONS

HOISTINGHOISTING

INSTRUCTIONS

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

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.

.

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 parts. part causthe part to be reof another

100%

88%

79%

71%

41%SAD00479

the part to the relative 2) Check for existence ing interference moved. with

WIRE ROPES I) Use adequate ropes depending on the to weight of parts to be hoisted, referring

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. 4) 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. When two ropes sling a load vertically, to 19.6 KN (2000 be suspended. hanging angle. kg) of total weight becomes This weight up can 9.8

the table below: Wire ropes (Standard Z or S twist ropes without galvanizing) Rope diameter mm 10 11.2 12.5 14 16 18 20 22.4 30 40 50 60 *

T

Allowable KN 9.8 13.7 15.7 21.6 27.5 35.3 43.1 54.9 98.1 176.5 274.6 392.2

load tons 1.0 1.4 1.6 2.2 2.8 3.6 4.4 5.6 10.0 18.0 28.0 40.0

KN (1000 kg) when two ropes make a 120 On the other hand, two force ropes are subjected to an excessive

as large as 39.2 KN (4000 kg) if they sling a 19.6 KN (2000 kg) load at a lifting angle of 150. 6 0 ~~~~~ 44 0

The allowable load value is estimated to be one-sixth or one-seventh of the breaking strength of the rope used. portion

2) Sling wire ropes from the middle of the hook.

30Lifting

60mole

90(degree)

120

150SAD00480

00-7

FOREWORD

COATING

MATERIALS

COATING

MATERIALScoating materials prescribed in Komatsu Shop Manuals are listed below.

The recommended

Category

Komatsu codeLT-1A

Part No.790-129-9030

Qty 150 g

ContainerTube

Main applications, features

**

Used to prevent rubber gaskets, rubber out and cork plugs from coming

cushions,

LT-1B

790-129-9050

20 g (x2)

Plastic container * *

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

LT-2 Adhesive

09940-00030

50 g Adhesive :I Kg Hardening I agent: :500 g 250 g

Plastic container

LT-3

790-129-9060 (Set of adhesivs and hardenginc

*Can

agent)LT-4 790-129-9040

Plastic container -

* . . *

Used

as sealant

for machined

holes

Loctite

646-50)

79A-129-9110 790-129-9010

50 cc

to heat, chemicals Features: Resistance subject to high Used at joint portions ture Used as adhesive packings of power for or sealant train case, etc.

temperaand

LG-1

200 g

gaskets

Tube

*LG-3 790-129-9070

1 Kg

Can

* * *

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, 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 for tapered piping threads, plugs,

LG-4

790-129-9020

200 g

Tube

with drive

pipe joints, elbows, nip-

IIRust prevention lubricant Molybdenum Iudisulphide bricant

LG-5

790-129-9080

1 Kg

Plastic container

*

09940-00011 250 g Tube * * * . * * LM-P 09940-00040 SYG-350LI SYG-400LI SYG-400LI-A SYG-16OLI SYGA-IGOCNL SSG2-400CA SYG2350CA SYG2-4OOCA-A SYG2-160CA SYGA-IGCNCA SYG2-400M 200 g Tube * . Various Various

LG-7

09920-00150

150 g

Tube

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

LM-G

09940-00051

60 g

Can

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 type

Lithium grease

G2-LI

Various Various

light load Used for normal temperature, at places in contact with water or steam

bearing

Calcium grease

G2-CA

400 g (IOpercas

-

Used for places with heavy

load

?)

I3ellows

type

-

00-8

FOREWORD

STANDARD

TIGHTENING

TORQUE

STANDARDSTANDARD

TIGHTENINGTORQUES

TORQUEOF BOLTS AND tightening NUTS torques of bolts and nuts. Exceptions are given

TIGHTENING

The following in section

charts give the standard

of DISASSEMBLY

AND ASSEMBLY. 1 Kgm = 9.806 Nm

Thread diameter of bolt mm6 8 IO 12 14 16 18 20 22 24 27 30 33 36 39

Width across flats mm IO13 17 19 22 24 27 30 32 36 41 46 50 55 60

TNm 13.2+ 1.4 31.4f2.9 65.7 * 6.8 112k9.8 177If: 19 279*29 383k39 549 k 58 745f78 927f98 1320f 1720* 140 190

SAD00481

SAD00482

1.35f0.15 3.2kO.3 6.7kO.7 11.5fl.O 18.0f2.0 28.5f3 39f4 56f6 76+8 94.5f 135f 10 15

175f20 225+25 280+30 335f35

2210f240 2750+290 3280 + 340

*

This torque table does not apply to the bolts with nonferrous metal washers are to be used, or which specified torque.

which nylon packings or other require tightening to otherwise

00-9

FOREWORD

STANDARD

TIGHTENING

TORQUE

TIGHTENING

TORQUE

OF SPLIT FLANGE for split flange bolts.

BOLTS

Use these torques

Thread diameter of bolt mm 10 12 16

Width across flats mm 14 17 22

INm 65.7f6.8 112f9.8 279k29

Tightening

torque kgm 6.7kO.7 11.5+1 28.5f3

TIGHTENING

TORQUE

FOR FLARED NUTS for flared part of nut.SAD00483

Use these torques

Thread diameter of nut part mm 14 18 22 24 30 33 36 42

Width across flats of nut part mm 19 24 27 32 36 41 46 55

TNm 24.5+ 4.9 49k 19.6 78.5f 19.6 137.3f29.4 176.5f29.4 196.1+49 245.2 f 49 294.2 f 49

Tightening

torque

Mm2.5f0.5 5f2 8+2 1453 18k3 20+5 25+5 30+5

00-10

FOREWORD

ELECTRIC WIRE CODE

ELECTRIC WIRE CODEIn 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

230

Starting

CLASSIFICATION

BY COLOR AND CODE

Color

-

-

-

Red & Blue

Yellow&White

Green

& Blue

-

FOREWORD

CONVERSION

TABLE

CONVERSIONMETHOD details OF USING

TABLETHE CONVERSION Table in this section TABLE is provided to enable simple conversion of figures. For Table, see the example given below.

The Conversion

of the method

of using the Conversion

EXAMPLE . 1. Method Convert (I) 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 line from @. (2) Locate the number 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. Convert 550 mm into inches. gives the value when converting 5 in the row across the top, take this as @, then draw a perpendicular line

(I) The number 550 does not appear in the table, so divide by IO (move the decimal point one placeto 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

to inches 0 0 IO 20 30 40 0 0.394 0.787 1.181 1.575 .. . . . . . . .1.969. .. 2.362 2.756 3.150 3.543 1 0.039 0.433 0.827 1.220 1.614 . . .. . . . .2.008. . . 2.402 2.795 3.189 3.583 2 0.079 0.472 0.866 1.260 1.654 3 0.118 0.512 0.906 1.299 1.693 4 0.157 0.551 0.945 1.339 1.732 5 0.197 0.591 0.984 1.378 1.772 6 0.236 0.630 1.024 1.417 1.811 2.205 2.598 2.992 3.386 3.780 7 0.276 0.669 1.063 1.457 1.850 2.244 2.638 3.032 3.425 3.819

1 mm = 0.03937

in

8 0.315 0.709 1.102 1.496 1.890 2.283 2.677 3.071 3.465 3.858

9 0.354 0.748 1.142 1.536 1.929 2.323 2.717 3.110 3.504 3.898

@-

... . . . 50. .. . . 60 70 80 90

. . .. .. . . .. . . . . . . . . .. . .2.047. . . . .2.087. ..I ..2.126 . . EE& 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..I

00-l 2

FOREWORD

CONVERSIONTABLE

Millimeters to Inches1 mm = 0.03937 in

3

4

5

6

7

8

9

0 10 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

2.047 2.441 2.835 3.228 3.622

2.087 2.480 2.874 3.268 3.661

2.126 2.520 2.913 3.307 3.701

2.165 2.559 2.953 3.346 3.740

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

Kilogram

to Pound

1 kg = 2.2046 lb 1 2.20 24.25 46.30 68.34 90.39 4 5 11.02 33.07 55.12 77.16 99.21 7 8 17.64 39.68 61.73 83.78 105.82

0

2 4.41 26.46 48.50 70.55 92.59

3 6.61 28.66 50.71 72.75 94.80

6 13.23 35.27 57.32 79.37 101.41

9

\0 10 20 30 40 0 22.05 44.09 66.14 88.18 8.82 30.86 51.91 74.96 97.00 15.43 37.48 59.53 81.57 103.62 19.84 41.89 63.93 85.98 108.03

50 60 70 80 90

110.23 132.28 154.32 176.37 198.42

112.44 134.48 156.53 178.57 200.62

114.64 136.69 158.73 180.78 202.83

116.85 138.89 160.94 182.98 205.03

119.05 141.10 163.14 185.19 207.24

121.25 143.30 165.35 187.39 209.44

123.46 145.51 167.55 189.60 211.64

125.66 147.71 169.76 191.80 213.85

127.87 149.91 171.96 194.01 216.05

130.07 152.12 174.17 196.21 218.26

00-13

FOREWORD

CONVERSIONTABLE

Liter to U.S. Gallon

It = 0.2642 U.S. Gal

0

1

2

3

4

5

6

7

8

9

0 IO 20 30 40

0 2.642 5.283 7.925 10.567

0.264 2.906 5.548 8.189 10.831

0.528 3.170 5.812 8.454 11.095

0.793 3.434 6.076 8.718 11.359

1.057 3.698 6:340 8.982 11.624

1.321 3.963 6.604 9.246 11.888

1.585 4.227 6.869 9.510 12.152

1.849 4.491 7.133 9.774 12.416

2.113 4.755 7.397 10.039 12.680

2.378 5.019 7.661 10.303 12.944

50 60 70 80 90

13.209 15.850 18.492 21.134 23.775

13.473 16.115 18.756 21.398 24.040

13.737 16.379 19.020 21.662 24.304

14.001 16.643 19.285 21.926 24.568

14.265 16.907 19.549 22.190 24.832

14.529 17.171 19.813 22.455 25.096

14.795 17.435 20.077 22.719 25.361

15.058 17.700 20.341 22.983 25.625

15.322 17.964 20.605 23.247 25.889

15.586 18.228 20.870 23.511 26.153

Liter to U.K. Gallon

It = 0.21997 U.K. Gal 2 3 5 67

0

1

4

8

9

0 10 20 30 40

0 2.200 4.399 6.599 8.799

0.220 2.420 4.619 6.819 9.019

0.440

0.660 2.860 5.059 7.259 9.459

0.880 3.080 5.279 7.479 9.679

1.100 3.300 5.499 7.969 9.899

1.320 3.520 5.719 7.919 10.119

1.540 3.740 5.939 8.139 10.339

1.760 3.950 6.159 8.359 10.559

1.980 4.179 6.379 8.579 10.778

2.640 4.839 7.039 9.239

50 60 70 80 90

0.998 3.198 15.398 17.598 19.797

11.281 13.418 15.618 17.818 20.017

11.438 13.638 15.838 18.037 20.237

11.658 13.858 16.058 18.257 20.457

11.878 14.078 16.278 18.477 20.677

12.098 14.298 16.498 18.697 20.897

12.318 14.518 16.718 18.917 21.117

12.528 14.738 16.938 19.137 21.337

12.758 14.958 17.158 19.357 21.557

12.978 15.178 17.378 19.577 21.777

00-14

FOREWORD

CONVERSIONTABLE

kgm to ft. lb1 kgm = 7.233 ft. lb

0

1

2

3

4

5

6

7

8

9

\\0 10 20 30 40 0 72.3 144.7 217.0 289.3 7.2 79.6 151.9 224.2 296.6 14.5 86.8 159.1 231.5 303.8 21.7 94.0 166.4 238.7 311.0 28.9 101.3 173.6 245.9 318.3 36.2 108.5 180.8 253.2 325.5 43.4 115.7 188.1 260.4 332.7 50.6 123.0 195.3 267.6 340.0 57.9 130.2 202.5 274.9 347.2 65.1 137.4 209.8 282.1 354.4

50 60 70 80 90

361.7 434.0 506.3 578.6 651.0

368.9 441.2 513.5 585.9 658.2

376.1 448.5 520.8 593.1 665.4

383.4 455.7 528.0 600.3 672.7

390.6 462.9 535.2 607.6 679.9

397.8 470.2 542.5 614.8 687.1

405.1 477.4 549.7 622.0 694.4

412.3 484.6 556.9 629.3 701.6

419.5 491.8 564.2 636.5 708.8

426.8 499.1 571.4 643.7 716.1

100 110 120 130 140

723.3 795.6 868.0 940.3 1012.6

730.5 802.9 875.2 947.5 1019.9

737.8 810.1 882.4 954.8 1027.1

745.0 817.3 889.7 962.0 1034.3

752.2 824.6 896.9 969.2 1041.5

759.5 831.8 904.1 976.5 1048.8

766.7 839.0 911.4 983.7 1056.0

773.9 846.3 918.6 990.9 1063.2

781.2 853.5 925.8 998.2 1070.5

788.4 860.7 933.1 1005.4 1077.7

150 160 170 180 190

1084.9 1157.3 1129.6 1301.9 1374.3

1092.2 1164.5 1236.8 1309.2 1381.5

1099.4 1171.7 1244.1 1316.4 1388.7

1106.6 1179.0 1251.3 1323.6 1396.0

1113.9 1186.2 1258.5 1330.9 1403.2

1121.1 1193.4 1265.8 1338.1 1410.4

1128.3 1200.7 1273.0 1345.3 1417.7

1135.6 1207.9 1280.1 1352.6 1424.9

1142.8 1215.1 1287.5 1359.8 1432.1

1150.0 1222.4 1294.7 1367.0 1439.4

00-l 5

FOREWORD

CONVERSIONTABLE

kg/cm*

to lb/in*1 kg/cm* = 14.2233 lb/id

\0 10 20 30 40

0

1

2

1

3

I

4

5

6

7

8

9

0 142.2 284.5 426.7 568.9

14.2 156.5 298.7 440.9 583.2

28.4 170.7 312.9 455.1 597.4

42.7 184.9 327.1 469.4 611.6

56.9 199.1 341.4 483.6 625.8

71.1 213.4 355.6 497.8 640.1

85.3 227.6 369.8 512.0 654.3

99.6 241.8 384.0 526.3 668.5

113.8 256.0 398.3 540.5 682.7

128.0 270.2 412.5 554.7 696.9

50 60 70 80 90

711.2 853.4 995.6 1138 1280

725.4 867.6 1010 1152 1294

739.6 881.8 1024 1166 1309

753.8 896.1 1038 1181 1323

768.1 910.3 1053 1195 1337

782.3 924.5 1067 1209 1351

796.5 938.7 1081 1223 1365

810.7 953.0 1095 1237 1380

825.0 967.2 1109 1252 1394

839.2 981.4 1124 1266 1408

100 110 120 130 140

1422 1565 1707 1849 1991

1437 1579 1721 1863 2005

1451 1593 1735 1877 2020

1465 1607 1749 1892 2034

1479 1621 1764 1906 2048

1493 1636 1778 1920 2062

1508 1650 1792 1934 2077

1522 1664 1806 1949 2091

1536 1678 1821 1963 2105

1550 1693 1835 1977 2119

150 160 170 180 190

2134 2276 2418 2560 2702

2148 2290 2432 2574 2717

2162 2304 2446 2589 2731

2176 2318 2460 2603 2745

2190 2333 2475 2617 2759

2205 2347 2489 2631 2773

2219 2361 2503 2646 2788

2233 2375 2518 2660 2802

2247 2389 2532 2674 2816

2262 2404 2546 2688 2830

200 210 220 230 240

2845 2987 3129 3271 3414

2859 3001 3143 3286 3428

2873 3015 3158 3300 3442

2887 3030 3172 3314 3456

2901 3044 3186 3328 3470

2916 3058 3200 3343 3485

2930 3072 3214 3357 3499

2944 3086 3229 3371 3513

2958 3101 3243 3385 3527

2973 3115 3257 3399 3542

00-l 6

FOREWORD

CONVERSION

TABLE

TemperatureFahrenheit-Centigrade Conversion ; a simple way to convert a Fahrenheit temperature 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 Ifitis desired to convert from Centigrade and read the corresponding Fahrenheit temperaturetemperature in the column at the left. to Fahrenheitdegrees,considerthecenter column as a table of Centigradevalues,

reading intoa Centigradetempera-

ture reading or vice versa isto enter the accompanying table in the center or boldfacecolumn of figures.

on the right. 1C = 33.8"F

C-40.4 -37.2 -34.4 -31.7 -28.9 -28.3 -27.8 -27.2 -26.7 -26.1 -25.6 -25.0 -24.4 -23.9 -23.3 -22.8 -22.2 -21.7 -21.1 -20.6 -20.0 -19.4 -18.9 -18.3 -17.8 -17.2 -16.7 -16.1 -15.6 -15.0 -14.4 -13.9 -13.3 -12.8 -12.2 -40 -35 -30 -25 -20 -19 -18 -17 -16 -15 -14 -13 -12 -11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10

F-40.0 -31.0 -22.0 -13.0 -4.0 -2.2 -0.4 1.4 3.2 5.0 6.8 8.6 10.4 12.2 14.0 15.8 17.6 19.4 21.2 23.0 24.8 26.6 28.4 30.2 32.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0

C-11.7 -11.1 -10.6 -10.0 -9.4 -8.9 -8.3 -7.8 -7.2 -6.7 -6.1 -5.6 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.7 -1.1 -0.6 0 0.6 1.1 1.7 2.2 2.8 3.3 3.9 4.4 5.0 5.6 6.1 6.7 7.2 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

F51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2 113.0

C7.8 8.3 8.9 9.4 10.0 10.6 11.1 11.7 12.2 12.8 13.3 13.9 14.4 15.0 15.6 16.1 16.7 17.2 17.8 18.3 18.9 19.4 20.0 20.6 21.1 21.7 22.2 22.8 23.3 23.9 24.4 25.0 25.6 26.1 26.7 46 47 46 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80

F114.8 116.6 118.4 120.2 122.0 123.8 125.6 127.4 129.2 131.0 132.8 134.6 136.4 138.2 140.0 141.8 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0

C27.2 27.8 28.3 28.9 29.4 30.0 30.6 31.1 31.7 32.2 32.8 33.3 33.9 34.4 35.0 35.6 36.1 36.7 37.2 37.8 40.6 43.3 46.1 48.9 51.7 54.4 57.2 60.0 62.7 65.6 68.3 71.1 73.9 76.7 79.4 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 105 110 115 120 125 130 135 140 145 150 155 160 165 170 175

F117.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.6 208.4 210.2 212.0 221.0 230.0 239.0 248.0 257.0 266.0 275.0 284.0 293.0 302.0 311.0 320.0 329.0 338.0 347.0

00-l 7

01

GENERAL

............... General assembly drawing .......................... Specifications Weight table ........................... ............... List of lubricant and water

Ol- 2 01- 3 Ol- 8 01-10

D275A-2

01-l

GENERAL ASSEMBLY DRAWINGSEMI U-DOZER WITH VARIABLE MULTIPLE RIPPER

17MF02001

01-2

D275A-2

SPECIFICATIONS

Machine

model 10001 - 10167

D275A-2 10168 and up

Serial numbers Operating weightl

Bare tractor With semi U-dozer Semi U-dozer with variable multiple ripper Semi U-dozer with variable multiple ripper + with ROPS cab assembly

37200 44180

l

l

kg

48830 50000

l

Minimum turning radius Grade ability Stabilitiy (Front, rear, left, right)7

m degree degree 0km/h 0-

3.9 30 35 3.8 6.7

1st 2nd 3rd

$ 2

O-11.8 0km/h 04.9 8.7

$ 1st & 2 2nd cT 3rd Bare tractor With Semi U-dozer

0 - 14.9 8.63 IO.881 10.29 (1.05) 11.37 11.16) 11.67 {1.19}

kPa Semi U-dozer with variable multiple ripper Semi U-dozer with variable multiple ripper (kg/cm*} + with ROPS cab assembly Bare tractor With Semi U-dozer Semi U-dozer with variable multiple ripper Bare tractor Wtih Semi U-dozer To top of exhaust pipe Except exhaust pipe, operatiors seat Track gauge Length of track on ground Show width Minimum ground clearance mm mm mm mm mm

5445 7085 9055 2935 4300 3875 2880 2260 3450 610 507

01-3 @

Machine

model10001 - 10167

D275A-210168 and up

Serial numbersEngine Type model

S6D170-1 4-cycle, water-cooled, in-line vertical, direct injection type with turbocharger x stroke mm cc kW/rpm :HP/rpmI Nm/rpm cgmlrpm rpm rpm ration g/kWh {glpshl 6-170x170 23150

S6D170-2 $-cycle, water-cooled, in-line vertical, direct injection type with turbocharger 6-170x170 23150

No. of cylinders-bore Piston displacement

Flywheel

horsepower

302/l ,800 141 O/l ,800) 2,079/l ,300 (2 12/l ,300) 2,000 630 214 {I581

302/I ,800 (41 O/l ,800) 2,079/l ,300 (2 12/l ,300) 2,000 630 224 {I651

Max. torque High idling speed Low idling speed Min. fuel consumption Starting Alternator Battery Radiator Torque core converter motor

24V, 7.5kw x 2 24V, 50A 12V, 170Ah x 2 ZG D type 3-element, l-stage, single phase (with lock-up clutch) 2 ;;

Transmission

Planetan/ gear, multiple disc clutch, hydraulically actuated, force-feed lubrication pump, forward B-speed, reverse 3-speed Spiral bevel gear, splash type lubrication Wet type, multiple clutch disc, spring boosted, hydraulically actuated (manual type), interconnected with 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 Semi-rigid balancing beam type 2 (each) 8 (each) Assembly type, single grouser 39 (each) mm mm 260.35 610

Bevel gear Steering clutch

Steering

brake

Final drive Suspension Carrier roller

Track roller Track shoe typel

No. of shoes Pitch Width

l

l

01-4 @

Machine

model

D275A-2

Serial numbersRelief valve setting Hydraulic Delivery pump type (at engine speed 1,800 rpm) L?/min

fRPafkglcm:

10001

- 10167

I20.6 (210)

10168

and

up

Gear type, 2 tandem 288

x 2EARlOO

+ 050)

. Blade

lift control

valve and ripper low valve

Single spool type with demand spool 3-tandem spool type 2-tandem pilot spool type

. Blade tilt controll

Ripper

high valve

Hydraulic

cylinder bore

type

Reciprocal, piston type 130

Cylinder Outside

diameter

of Piston rod mm

80 1,420 2,365 945 200

Piston stroke Max. distance Min. distance Cylinder Outside bore diameter of Piston rod between between Pins Pins

100 mm 190 1,555 1,365 200

Piston stroke Max. distance between between Pins Pins

Min. distance Cylinder Outside bore

diameter

of Piston rod mm

100 465 1,565 1,100

Piston stroke Max. distance Min. distance between between Pins Pins

01-5 @

ork.equipment W Dozer equipment Jin puller cylinder Dual tilt cylinder Gpper tilt cylinder efformance limension

Hydraulic cylinder

21D L

R

017M02

Machine

model10001 - 10167

D275A-2 10168

Serial numbers TypeWeight Beam length No. of shanks Ripping Ripping angle depth depth mm mm (standard) degree

I

and uptype

Variable angle type, parallelogram

kgmm

4,490 2,495 3 51.7 (Possible to adjust steplessly 36.9 - 61.2) P-stage selection possible 900 955 Variable angle type, parallelogram type

Max. digging

Max. lifting height Type Weight Beam length No. of shanks Ripping Ripping angle depth depth height (standard)

kgmm

3,640 1,252 1

degree

52.7 (Possible to adjust steplessly 39.7 - 62.2) 3-stage selection possible

Max. digging Max. lifting

mm mm

1.300 870

01-7 @

WEIGHT TABLE

A

This weight table is a guide for use when transporting or handling components. Machine modelSerial numbers

Unit: kg

D275A-2

10001 and up

Engine and damper assemblyl

2810 2580 160 70 350 100 390 (1150)

Engine assembly Damper assembly Engine mounting parts

l

l

Radiator assembly Oil cooler assembly Fuel tank assembly (Full) Power train unit Power train assembly Torque converter and PTO assembly Transmission Transmission assembly control valve assembly

3360 740 890 35 1600 60 1940 4200 4100 1200 340 110 120 70 6800 145 255 195 350 56 47

Steering clutch and brake assembly Steering control valve assembly Final drive assembly (each side) Main frame assembly Track group assembly (each side) Track frame Idler assembly Track roller assembly (single) (each) Track roller assembly (double) (each) Carrier roller assembly (each) Track shoe assembly (width 610 mm) Pivot shaft (each side) Equalizer bar Bolster Hydraulic tank assemblyl

Blade lift control valve assembly Blade tilt and ripper low valve assmebly

l

01-8

D275A-2

Unit: kg Machine model Serial numbers D275A-2

I

10001 and up 6330 2980 780 780 220

Semi-U dozer assemblyl

Blade L.H. straight frame R.H. straight frame Tilt cylinder assembly

l

l

l

Variable multiple shank ripper assemblyl

Shank assembly (each) Lift cylinder assembly Tilt cylinder assembly

350 205 185 3600 500 205 185 1700 750 210 330 260 330 90 300 320 500 580 320 490 70

l

l

Variable giant ripper assemblyl

Shank assembly Lift cylinder assembly Tilt cylinder assembly

l

l

Radiator guard assembly (with cylinder yoke)l

Radiator guard Blade lift cylinder assembly (each side)

l

Front guard (with grille) Engine under guard Power train under guard Engine hood L.H. fender R.H. fender ROPS mount assembly ROPS assembly Floor frame assembly Cab assembly Operators seat assembly

D275A-2

01-9

TABLE OF FUEL, COOLANT AND LUBRICANTS

RESERVOIR

KIND OF FLUID

AMBIENT TEMPERATURE-22 -4

Engine oil pan

Power train oil pan (Incl. torque converter, transmission and bevel gear case) Engine oil

Hydraulic tank

I

*I

Gear oil

Fuel tank

Diesel fuel

Cooling system

I

Coolant

Add antifreeze

136

-

*

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 %

l/4 of regular interval

ASTM: SAE: API:

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 OC, be sure to use and SAEIOW-30 oil of SAEIOW, engine even though an atmospheric temSAEl5W-40 perature goes up to 10C 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 @ .*-

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

6. 7. 8. 9. 10. 11.

Transfer Steering clutch Steering brake Final drive Sprocket Track

F19702001

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).

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).

1 o-2

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

I4D275A-2 10061 and up

8

SI

A61. 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 dividedinto 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.

Main frame PTO Torque converter Transmission Steering clutch and brake Cage

7. 8. 9. 10. 11.

Clamp Seal Cover Coupling Cap

D275A-2

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

?

setpressure2.7 kg/cm2

!rpressure i--J Se 1!7I f 1 kg/cm2 :racking ,VZSE

!t

Cracking pressw 1.4 kg/cm2

iri

1:

.4 kg/cm*

;46F17M02001A

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. 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

E6

1 O-8 0

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

PTO1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

C.

17MF02008

A. B. C.

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

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

10-12

D275A-2

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

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).

D275A-2

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

110 ,,,I

11

12

13

Lock-up clutch

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)

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. Lock-up clutch pressure 3 pickup port P,: Main relief pressure pickup port P10' Lock-up clutch initial . pressure pickup port P11'* Stator clutch initial pressure pickup port P:

lo-16

D275A-2

E-E

8

E6

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

QFrom pump F19702004

To torque converter

To oil tank

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 torque converter

From pump F19702005 To oil tank

From pump

F19702006

lo-18

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 operators 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

E6

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-pgrod

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

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.

1O-20

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).

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.

D275A-2

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

To solenoid valve

_ II

197FO2027

From pump

To solenoid valve

//ID275A-2

I

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.

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.

1 O-24

D275A-2

1

\

5

\

f

:

8 \

9 \

1,s

17

l,B

;2

/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 Neutral First speed Forward Second Third Neutral First speed Reverse Second Third speed speed speed speed

Operating No. 5 clutch No. 2 and

clutch

No. 5 clutches

No. 2 and No. 4 clutches No. 2 and No. 3 clutches No. 5 clutch No. 1 and No. 5 clutches No. 1 and No. 4 clutches 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 No. 2 clutch No. 3 clutch No. 4 clutch No. 5 clutch

5 4 2 3 4

5 5 3 3 5

40 /////I 39

38

37

36

35

I 34

/ 33

I 32

I 31

I 30

I 29

I 28

I 27

\

4

17MF02016

D275A-2

1 o-25

FUNCTION

OF PISTON 3.7 4.2 3.! 38 36 35

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 discs internal teeth engage with the ring gears 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 discs internal teeth is locked.

39

3p

36C

?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

3017MF02017

I

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).

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).

D275A-2

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).

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).

1 O-28

D275A-2

TRANSMISSION

CONTROL

1. 2. 3. 4. 5.

Gear shift lever Safety lever F-R spool linkage Speed spool linkage Transmission control

17MF02019

valve

D275A-2

1 O-29

TRANSMISSION

CONTROL VALVE

E-E

17MF02020

Modulating pressure Reducing pressure

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)

1O-30

D275A-2

A-A

18

K

JB-B

H

1911. 12. 13. 14. 15. 16. 17. 18. 19.

17MF :02021

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

Reducing valve Stopper Reducing valve spring Stopper Modulating sleeve spring (Small) Stopper Piston F-R valve Speed valve

D275A-2

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 -

0 0

I

,

(Sec.)1 I I , , , ,

0.5 Time

1.0

1JMF02022

1 O-32 0

Operation 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).

From pump

TO clutch cylinder

Drain

6A From pump

17MF02023

,E

\

F

6

17MF02024

To clutch cylinder

Drain

\ 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 pump

G \

17MF02026

\From / PumA

To

clutchcylinder17MF02027

1o-34

D275A-2

REDUCING

VALVE

l

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.

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

131

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 mo