Complete service repair manual for Komatsu Bulldozer D135A-2, with technical information to maintain, diagnose, repair, and service like professional mechanics.
Komatsu Bulldozer D135A workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
SEBM015A0206 – Bulldozer D135A-2 Shop Manual (SN10301&up).pdf
SEAM015A0201 – Bulldozer D135A-2 Operation & Maintenance Manual.pdf
PRODUCT DETAILS:
Total Pages: 479 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
SEAM015A0201 – Bulldozer D135A-2 Operation & Maintenance Manual…..2
COVER…..2
FOREWORD…..3
BREAKING IN YOUR NEW MACHINE…..4
CONTENTS…..5
GENERAL LOCATIONS AND SPECIFICATIONS…..6
INSTRUMENTS AND CONTROLS …..8
CHECK BEFORE STARTING…..38
OPERATING YOUR MACHINE…..44
COLD WEATHER OPERATION…..64
METHOD FOR RELEASING WHEN ASSIST BRAKE HAS BEEN APPLIED…..69
OPERATING RIPPER…..73
BULLDOZER’S WORK…..77
TIPS FOR LONGER UNDERCARRIAGE LIFE…..79
ADJUSTMENT OF WORK EQUIPMENT…..81
HOW TO REVERSE THE REVERSIBLE FAN…..85
SELECTION OF RIPPER POINT…..87
PERIODIC MAINTENANCE…..88
PERIODICAL REPLACEMENT OF SAFETY…..89
MAINTENANCE TABLE…..92
OIL FILLER AND LEVEL GAUGE POSITIONS…..96
EVERY 250 HOURS SERVICE…..98
EVERY 500 HOURS SERVICE…..108
EVERY 1000 HOURS SERVICE…..112
EVERY 2000 HOURS SERVICE…..118
EVERY 4000 HOURS SERVICE…..121
WHEN REQUIRED…..122
ADJUSTMENT…..134
TROUBLE SHOOTING GUIDE…..142
SERVICE METER…..146
MACHINE AND ENGINE SERIAL NUMBERS…..148
FUEL,COOLANT AND LUBRICANTS…..150
SAFETY AND OPERATION…..152
CONTENTS…..153
SAFETY HINTS…..154
PRECAUTIONS FOR MAINTENANCE…..168
CAR STEREO…..174
AIR CONDITIONER…..177
LOCKING CAP…..185
HANDLING OF BATTERY…..187
STORAGE…..190
COOLANT AND LUBRICANTS…..191
SEBM015A0206 – Bulldozer D135A-2 Shop Manual (SN10301&up)…..193
COVER…..193
CONTENTS…..194
10 STRUCTURE AND FUNCTION…..215
GENERAL…..216
POWER TRAIN HYDRAULIC SYSTEM…..218
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM…..219
TORQUE CONVERTER…..220
TORQFLOW TRANSMISSION…..224
TRANSMISSION CONTROL…..230
TORQFLOW HYDRAULIC PIPING…..231
TORQFLOW HYDRAULIC SYSTEM…..232
TORQFLOW HYDRAULIC CIRCUIT DIAGRAM…..233
TRANSMISSION CONTROL VALVE…..234
TRANSMISSION LUBRICATION RELIEF VALVE…..239
TRANSMISSION PUMP…..240
TRANSMISSION AND STEERING OIL STRAINER…..241
TRANSMISSION OIL FILTER…..242
BEVEL GEAR SHAFT AND STEERING CLUTCH…..243
STEERING CONTROL…..245
STEERING AND BRAKE PIPING…..246
STEERING AND BRAKE HYDRAULIC SYSTEM…..247
STEERING AND BRAKE HYDRAULIC CIRCUIT DIAGRAM…..248
STEERING PUMP…..249
STEERING MAIN RELIEF VALVE…..250
STEERING AND BRAKE CONTROL VALVE…..251
STEERING BRAKE…..255
SPRING ASSIST BRAKE SYSTEM…..259
FINAL DRIVE…..263
PTO (POWER TAKE OFF)…..264
TRACK FRAME…..265
IDLER CUSHION…..266
IDLER…..267
TRACK ROLLER AND CARRIER ROLLER…..268
TRACK (LUBRICATED TRACK LINK)…..269
TRACK (DRY TYPE TRACK LINK)…..270
SUSPENSION…..271
HYDRAULIC PIPING…..272
HYDRAULIC CONTROL…..274
HYDRAULIC SYSTEM (WITHOUT RIPPER)…..276
HYDRAULIC CIRCUIT DIAGRAM (WITHOUT RIPPER)…..277
HYDRAULIC SYSTEM (WITH RIPPER)…..278
HYDRAULIC CIRCUIT DIAGRAM (WITH RIPPER)…..279
HYDRAULIC TANK (WITHOUT RIPPER)…..280
HYDRAULIC TANK (WITH RIPPER)…..281
HYDRAULIC PUMP…..282
BLADE CONTROL VALVE…..283
MAIN RELIEF VALVE (WITHOUT RIPPER)…..290
RIPPER CONTROL VALVE…..291
HYDRAULIC LEVER OPERATION…..296
HYDRAULIC CYLINDER…..300
CYLINDER STAY…..304
STRAIGHT TILTDOZER…..305
VARIABLE MULTIPLE SHANK RIPPER…..307
ELECTRICAL CIRCUIT DIAGRAM…..309
EVMS (ELECTRONIC VEHICLE MONITORING SYSTEM)…..311
AIR CONDITIONER…..317
20 TESTING AND ADJUSTING…..319
TABLE OF STANDARD VALUES FOR ENGINE…..320
TABLE OF STANDARD VALUES FOR CHASSIS…..321
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE…..326
TESTING AND ADJUSTING…..328
TESTING AND ADJUSTING TOOL LIST…..329
ADJUSTING VALVE CLEARANCE…..330
MEASURING COMPRESSION PRESSURE…..331
TESTING AND ADJUSTING FUEL INJECTION TIMING…..332
MEASURING TORQUE CONVERTER STALL SPEED…..333
BLEEDING AIR FROM FUEL SYSTEM…..334
BLEEDING AIR FROM HYDRAULIC CYLINDER…..334
MEASURING OIL PRESSURE…..335
ADJUSTING FUEL CONTROL LINKAGE…..337
ADJUSTING GEAR SHIFT LEVER LINKAGE…..339
ADJUSTING STEERING CLUTCH LINKAGE…..341
ADJUSTING BRAKE PEDAL TRAVEL…..342
ADJUSTING BRAKE PEDAL LINKAGE…..343
ADJUSTING BRAKE CONTROL LINKAGE…..345
ADJUSTING RIPPER CONTROL LINKAGE…..346
ADJUSTING CLEARANCE OF IDLER…..347
H-MODE TROUBLESHOOTING…..349
PREPARATION FOR TROUBLESHOOTING…..350
METHOD OF READING TROUBLESHOOTING TABLE…..352
PREVENTING RECURRENCE OF THE SAME TROUBLE…..354
TROUBLESHOOTING…..355
H-1 TORQUE CONVERTER TEMPERATURE TOO HIGH…..355
H-2 MACHINE DOES NOT MOVE…..356
H-3 MACHINE LACKS POWER OR SPEED…..358
H-4 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR…..359
H-5 MACHINE MOVES WHEN ENGINE IS STARTED…..360
H-6 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR…..360
H-7 MACHINE TRAVELS IN ONE DIRECTION ONLY (FORWARD OR REVERSE)…..360
H-8 STEERING CLUTCH DOES NOT DISENGAGE…..361
H-9 STEERING CLUTCH SLIPS…..362
H-10 STEERING BRAKE DOES NOT WORK…..363
H-11 BLADE LIFT LACKS POWER AND SPEED…..364
H-12 BLADE DOES NOT LIFT…..365
H-13 THE FRONT OF MACHINE CANNOT BE RAISED OFF GROUND BY THE BLADE…..366
H-14 HYDRAULIC DRIFT OF LIFT CYLINDER IS LARGE…..367
H-15 BLADE MOVES UNSTEADILY WHEN LEVELING THE GROUND (CONTROL LEVER IN "HOLD")…..368
H-16 BLADE LOWERS UNDER THE FOLLOWING CONDITIONS…..368
H-17 TRAVEL OF THE PISTON RODS IN THE RIGHT AND LEFT LIFT CYLINDERS IS DIFFERENT(APPLICABLE TO STRAIGHT -TILT DOZER ONLY)…..368
H-18 BLADE TILTING FORCE IS LACK, BLADE TILTING SPEED IS SLOW, THE MACHINE CANNOT BE RAISED OFF GROUND BY BLADE TILTING FORCE…..369
H-19 TILT CYLINDER DOES NOT MOVE OFF (TILTING IS IMPOSSIBLE)…..370
H-20 HYDRAULIC DRIFT OF TILT CYLINDER IS LARGE…..371
H-21 HYDRAULIC DRIFT OF RIPPER CYLINDER IS LARGE…..372
H-22 OPERATING FORCE IS HEAVY…..373
M-MODE TROUBLESHOOTING…..374
POSITION OF CONNECTORS FOR TROUBLESHOOTING…..375
CONNECTOR TYPE AND MOUNTING POSITION…..376
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..377
PROCEDURE FOR TROUBLESHOOTING…..381
CHECKS BEFORE TROUBLESHOOTING…..382
METHOD OF USING TROUBLESHOOTING CHART…..383
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)…..385
M-1 NO MONITOR PANEL DISPLAY IS GIVEN WHEN STARTING SWITCH IS TURNED ON…..386
M-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MONITOR PANEL STAY LIGHTED AND DO NOT GO OUT…..386
M-3 WHEN STARTING SWITCH IS ON (ENGINE STOPPED), CHECK ITEMS FLASH. (CHECK ITEM LEVELS ARE AT SPECIFIED LEVEL)…..387
M-4 NO PREHEATING IS BEING CARRIED OUT, BUT PREHEATING DISPLAY LIGHTS UP…..388
M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH…..389
M-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CAUTION ITEMS FLASH…..390
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), CAUTION ITEMS FLASH. (WHEN THERE IS AN ABNORMALITY IN THE ENGINE OR IN THE CHECK ITEMS.)…..391
M-8 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), BUZZER DOES NOT SOUND FOR ONE SECOND…..394
a) CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND…..394
b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY,BUT BUZZER SOUNDS…..394
M-9 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED), LAMPS DO NOT LIGHT UP FOR 2 SECONDS…..395
a) CAUTION ITEM IS FLASHING,BUT WARNING LAMPS DOES NOT FLASH…..395
b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY,BUT LAMPS LIGHT UP…..395
M-10 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP…..396
M-11 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED…..397
M-12 WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE…..398
M-13 WATER TEMPERATURE GAUGE GIVES NO DISPLAY…..398
M-14 TORQUE CONVERTER OIL TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE…..399
M-15 TORQUE CONVERTER OIL TEMPERATURE GAUGE GIVES NO DISPLAY…..399
M-16 FUEL GAUGE ALWAYS DISPLAYS TANK FULL…..400
M-17 FUEL GAUGE GIVES NO DISPLAY…..400
30 DISASSEMBLY AND ASSEMBLY…..401
METHOD OF USING MANUAL…..403
PRECAUTIONS WHEN CARRYING OUT OPERATION…..404
SPECIAL TOOL LIST…..406
WEIGHT TABLE…..411
TABLE OF TIGHTENING TORQUE AND STANDARD VALUE…..413
TABLE OF OIL AND COOLANT QUANTITIES…..426
PRECAUTIONS WHEN HANDLING PIPING DURING DISASSEMBLY…..427
STARTING MOTOR…..429
REMOVAL…..429
INSTALLATION…..429
ALTERNATOR…..429
REMOVAL…..429
INSTALLATION…..429
AIR COMPRESSOR…..429
REMOVAL…..429
INSTALLATION…..429
NOZZLE HOLDER…..431
REMOVAL…..431
INSTALLATION…..431
FUEL INJECTION PUMP…..431
REMOVAL…..431
INSTALLATION…..431
ENGINE OIL COOLER…..433
REMOVAL…..433
INSTALLATION…..433
THERMOSTAT…..433
REMOVAL…..433
INSTALLATION…..433
WATER PUMP…..433
REMOVAL…..433
INSTALLATION…..433
TURBOCHARGER…..433
REMOVAL…..433
INSTALLATION…..433
CYLINDER HEAD…..435
REMOVAL…..435
INSTALLATION…..439
RADIATOR GUARD…..441
REMOVAL…..441
INSTALLATION…..441
RADIATOR…..443
REMOVAL…..443
INSTALLATION…..443
PTO…..443
REMOVAL…..443
INSTALLATION…..443
DISASSEMBLY…..445
ASSEMBLY…..447
FUEL TANK…..449
REMOVAL…..449
INSTALLATION…..449
ENGINE…..451
REMOVAL…..451
INSTALLATION…..455
TORQUE CONVERTER…..457
REMOVAL…..457
INSTALLATION…..457
DISASSEMBLY…..459
ASSEMBLY…..465
TORQUE CONVERTER RELIEF VALVE…..471
REMOVAL…..471
INSTALLATION…..471
DISASSEMBLY…..471
ASSEMBLY…..471
TORQUE CONVERTER REGULATOR VALVE…..471
REMOVAL…..471
INSTALLATION…..471
DISASSEMBLY…..471
ASSEMBLY…..471
TRANSMISSION…..473
REMOVAL…..473
INSTALLATION…..473
DISASSEMBLY…..475
ASSEMBLY…..487
TRANSMISSION CONTROL VALVE…..501
REMOVAL…..501
INSTALLATION…..501
DISASSEMBLY…..503
ASSEMBLY…..505
TRANSMISSION LUBRICATION VALVE…..507
REMOVAL…..507
INSTALLATION…..507
DISASSEMBLY…..507
ASSEMBLY…..507
BEVEL GEAR AND SHAFT…..509
DISASSEMBLY…..509
ASSEMBLY…..511
STEERING CLUTCH…..517
REMOVAL…..517
INSTALLATION…..517
DISASSEMBLY…..519
ASSEMBLY…..519
STEERING RELIEF VALVE…..521
REMOVAL…..521
INSTALLATION…..521
DISASSEMBLY…..521
ASSEMBLY…..521
BRAKE BOOSTER…..523
DISASSEMBLY…..523
ASSEMBLY…..523
STEERING AND BRAKE VALVE…..523
REMOVAL…..523
INSTALLATION…..523
DISASSEMBLY…..525
ASSEMBLY…..525
TRANSMISSION PUMP…..527
REMOVAL…..527
INSTALLATION…..527
STEERING PUMP…..527
REMOVAL…..527
INSTALLATION…..527
ASSIST BRAKE CYLINDER…..527
REMOVAL…..527
INSTALLATION…..527
DISASSEMBLY…..529
ASSEMBLY…..531
NO.1 PINION…..535
DISASSEMBLY…..535
ASSEMBLY…..537
FINAL DRIVE…..539
DISASSEMBLY…..539
ASSEMBLY…..543
TRACK FRAME…..549
REMOVAL…..549
INSTALLATION…..549
RECOIL SPRING…..551
REMOVAL…..551
INSTALLATION…..551
DISASSEMBLY…..553
ASSEMBLY…..553
IDLER…..555
REMOVAL…..555
INSTALLATION…..555
TRACK ROLLER…..555
REMOVAL…..555
INSTALLATION…..555
CARRIER ROLLER…..557
REMOVAL…..557
INSTALLATION…..557
TRACK SHOE…..557
REMOVAL…..557
INSTALLATION…..557
OVERALL DISASSEMBLY…..559
OVERALL ASSEMBLY…..564
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS…..580
FIELD DISASSEMBLY OF ONE LINK…..581
FIELD ASSEMBLY OF ONE LINK…..583
DISASSEMBLY OF MASTER LINK…..585
ASSEMBLY OF MASTER LINK…..587
HYDRAULIC PUMP…..590
REMOVAL…..590
INSTALLATION…..590
BLADE CONTROL VALVE…..590
REMOVAL…..590
INSTALLATION…..590
DISASSEMBLY…..592
ASSEMBLY…..594
RIPPER CONTROL VALVE…..596
REMOVAL…..596
INSTALLATION…..596
DISASSEMBLY…..596
ASSEMBLY…..596
BLADE RELIEF VALVE…..598
DISASSEMBLY…..598
ASSEMBLY…..598
RIPPER RELIEF VALVE…..598
DISASSEMBLY…..598
ASSEMBLY…..598
BLADE LIFT CYLINDER…..600
REMOVAL…..600
INSTALLATION…..600
BLADE TILT CYLINDER…..600
REMOVAL…..600
INSTALLATION…..600
RIPPER LIFT CYLINDER…..602
REMOVAL…..602
INSTALLATION…..602
RIPPER TILT CYLINDER…..602
REMOVAL…..602
INSTALLATION…..602
HYDRAULIC CYLINDER…..604
DISASSEMBLY…..604
ASSEMBLY…..608
BLADE…..612
REMOVAL…..612
INSTALLATION…..612
DISASSEMBLY…..614
ASSEMBLY…..614
MULTIPLE SHANK RIPPER…..616
DISASSEMBLY…..616
ASSEMBLY…..616
CAB…..618
REMOVAL…..618
INSTALLATION…..618
TURNING OVER ROPS CAB…..620
REMOVAL…..620
INSTALLATION…..622
40 MAINTENANCE STANDARD…..624
TORQUE CONVERTER…..625
TORQFLOW TRANSMISSION…..627
TRANSMISSION CONTROL VALVE…..629
TRANSMISSION LUBRICATION VALVE…..631
TRANSMISSION PUMP…..632
BEVEL GEAR SHAFT…..633
STEERING CLUTCH…..635
STEERING PUMP…..637
STEERING MAIN RELIEF VALVE…..638
STEERING AND BRAKE CONTROL VALVE…..639
STEERING BRAKE …..641
ASSIST BRAKE CYLINDER…..643
ASSIST BRAKE AUTOMATIC DRAIN VALVE…..644
FINAL DRIVE…..645
TRACK FRAME…..647
RECOIL SPRING…..648
IDLER…..649
TRACK ROLLER…..651
CARRIER ROLLER…..653
TRACK…..654
SUSPENSION…..658
HYDRAULIC PUMP…..659
BLADE CONTROL VALVE…..660
RIPPER CONTROL VALVE…..662
HYDRAULIC CYLINDER…..664
CYLINDER STAY…..667
STRAIGHT TILTDOZER…..668
VARIABLE MULTI-SHANK RIPPER…..670
Komatsu Bulldozer D135A Repair Service Manuals