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