Komatsu Bulldozer D85E-SS-2 Shop Manual LEBMD08200 – PDF DOWNLOAD

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Komatsu Bulldozer D85E-SS-2 Shop Manual LEBMD08200 – PDF DOWNLOAD

FILE DETAILS:

Komatsu Bulldozer D85E-SS-2 Shop Manual LEBMD08200 – PDF DOWNLOAD

Language : English
Pages :587
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu Bulldozer D85E-SS-2 Shop Manual LEBMD08200 – PDF DOWNLOAD

FOREWORD GENERAL

This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judge­ ments. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are fur­ their divided into the each main group of components.

TABLE OF CONTENTS:

Komatsu Bulldozer D85E-SS-2 Shop Manual LEBMD08200 – PDF DOWNLOAD

COVER130
CONTENTS 2
01 GENERAL 26
GENERAL ASSEMBLY DRAWING 27
SPECIFICATIONS 28
WEIGHT TABLE 31
TABLE OF FUEL, COOLANT AND LUBRICANTS 33
10 STRUCTURE AND FUNCTION 35
RADIATOR, OIL COOLER 36
ENGINE CONTROL 38
POWER TRAIN SYSTEM 40
POWER TRAIN SKELETON 41
POWER TRAIN UNIT 42
POWER TRAIN HYDRAULIC PIPING DIAGRAM 43
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 45
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM 46
DAMPER, UNIVERSAL JOINT 47
TORQUE CONVERTER AND PTO 49
TRANSMISSION CONTROL 51
TRANSMISSION 53
TRANSMISSION CONTROL VALVE 59
MAIN RELIEF VALVE 66
LUBRICATION RELIEF VALVE 68
STEERING, BRAKE CONTROL 69
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 70
STEERING CONTROL VALVE 76
REDUCING VALVE 83
SCAVENGING PUMP STARAINER 84
POWER TRAIN OIL STRAINER 85
POWER TRAIN OIL FILTER 86
FINAL DRIVE 87
MAIN FRAME 90
TRACK FRAME 91
RECOIL SPRING 93
SUSPENSION 95
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 99
WORK EQUIPMENT CONTROL101
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM102
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM103
HYDRAULIC TANK AND FILTER104
MAIN CONTROL VALVE108
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT110
PISTON VALVE111
WORK EQUIPMENT112
ELECTRICAL CIRCUIT DIAGRAM113
ENGINE CONTROL114
MACHINE MONITOR SYSTEM115
SENSORS118
20 TESTING AND ADJUSTING120
STANDARD VALUE TABLE FOR ENGINE121
STANDARD VALUE TABLE FOR CHASSIS123
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM127
TOOL LIST FOR TESTING AND ADJUSTING131
ADJUSTING VALVE CLEARANCE132
MEASURING COMPRESSION PRESSURE133
MEASURING BLOWBY134
ADJUSTING FUEL INJECTION TIMING135
MEASURING EXHAUST COLOR137
MEASURING BOOST PRESSURE138
MEASURING EXHAUST TEMPERATURE139
MEASURING ENGINE OIL PRESSURE140
MEASURING ENGINE SPEED140
TESTING FAN BELT TENSION141
MEASURING SPEED AT TORQUE CONVERTER STALL142
ADJUSTING FUEL CONTROL LINKAGE143
ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE147
ADJUSTING BRAKE PEDAL LINKAGE151
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE152
MEASURING POWER TRAIN OIL PRESSURE153
MEASURING AND ADJUSTING BLADE CONTROL OIL PRESSURE160
BLEEDING AIR FROM HYDRAULIC CYLINDER161
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT161
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE162
PROCEDURE FOR TESTING SENSORS163
TROUBLESHOOTING164
POINTS TO REMEMBER WHEN TROUBLESHOOTING165
SEQUENCE OF EVENTS IN TROUBLESHOOTING166
POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE167
CHECK BEFORE TROUBLESHOOTING175
METHOD OF USING TROUBLESHOOTING CHARTS180
TYPE OF CONNECTOR AND POSITION OF INSTALLATION182
CONNECTOR POSITION DRAWING183
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS184
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM194
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)195
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)196
S-2 ENGINE DOES NOT START197
① ENGINE DOES NOT TURN197
② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)198
③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)199
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)200
S-4 ENGINE STOPS DURING OPERATIONS201
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)202
S-6 ENGINE LACKS OUTPUT (NO POWER)203
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)204
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)205
S-9 OIL BECOMES CONTAMINATED QUICKLY206
S-10 FUEL CONSUMPTION IS EXCESSIVE207
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN208
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)209
S-13 OIL LEVEL RISES210
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)211
S-15 ABNORMAL NOISE IS MADE212
S-16 VIBRATION IS EXCESSIVE213
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)214
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM)215
H-1 BRAKES DOES NOT WORK216
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN S STRAIGHT LINE)217
H-3 OVERTURNS WHEN TURING218
H-4 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING AND DIRECTIONAL LEVER IS OPERATED)219
H-5 EXCESSIVE TIME LAG220
H-6 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)220
H-7 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)221
H-8 MACHINE DOES NOT MOVE IN AND SPEED RANGE223
H-9 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH225
H-10 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW227
H-11 ABNORMAL NOISE IS GENERATED FROM AROUND HYDRAULIC PUMP229
H-12 BLADE LIFTING SPEED IS SLOW OR LACKS POWER230
H-13 BLADE DOES NOT RAISE231
H-14 HYDRAULIC DRIFT OF BLADE LIFT IS EXCESSIVE231
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)232
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)233
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON 234
E-2 LAMPS DO NO LIGHT UP236
a) FRONT LAMPS236
b) REAR LAMPS237
E-3 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO238
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)242
M-1 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE243
M-2 ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE244
30 DISASSEMBLY AND ASSEMBLY245
METHOD OF USING MANUAL247
PRECAUTIONS WHEN CARRYING OUT OPERATION250
SPECIAL TOOL LIST252
STARTING MOTOR256
REMOVAL256
INSTALLATION256
ALTERNATOR257
REMOVAL257
INSTALLATION257
ENGINE OIL COOLER CORE259
REMOVAL259
INSTALLATION259
FUEL INJECTION PUMP260
REMOVAL260
INSTALLATION261
WATER PUMP262
REMOVAL262
INSTALLATION262
TURBOCHARGER264
REMOVAL264
INSTALLATION264
NOZZLE HOLDER265
REMOVAL265
INSTALLATION265
THERMOSTAT266
REMOVAL266
INSTALLATION266
CYLINDER HEAD268
REMOVAL268
INSTALLATION271
ENGINE FRONT SEAL278
REMOVAL278
INSTALLATION279
ENGINE REAR SEAL280
REMOVAL280
INSTALLATION281
FUEL TANK284
REMOVAL284
INSTALLATION284
RADIATOR287
REMOVAL287
INSTALLATION289
HYDRAULIC OIL COOLER289
REMOVAL289
INSTALLATION289
ENGINE290
REMOVAL290
INSTALLATION292
DAMPER296
REMOVAL296
INSTALLATION298
POWER TRAIN UNIT301
REMOVAL301
INSTALLATION306
SEPARATION307
CONNECTION309
TORQUE CONVERTER310
DISASSEMBLY310
ASSEMBLY312
PTO315
DISASSEMBLY315
ASSEMBLY318
TORQFLOW TRANSMISSION322
DISASSEMBLY322
ASSEMBLY331
STEERING CASE345
DISASSEMBLY345
ASSEMBLY351
TORQUE CONVERTER VALVE362
REMOVAL362
INSTALLATION362
DISASSEMBLY363
ASSEMBLY363
TRANSMISSION CONTROL VALVE364
REMOVAL364
INSTALLATION364
DISASSEMBLY366
ASSEMBLY366
STEERING CONTROL VALVE371
REMOVAL371
INSTALLATION371
DISASSEMBLY372
ASSEMBLY374
REDUCING VALVE376
REMOVAL376
INSTALLATION376
DISASSEMBLY377
ASSEMBLY377
SCAVENGING PUMP378
REMOVAL378
INSTALLATION378
POWER TRAIN PUMP379
REMOVAL379
INSTALLATION379
FINAL DRIVE380
REMOVAL380
INSTALLATION381
DISASSEMBLY382
ASSEMBLY386
TRACK FRAME391
REMOVAL391
INSTALLATION392
RECOIL SPRING393
REMOVAL393
INSTALLATION393
DISASSEMBLY394
ASSEMBLY396
IDLER402
REMOVAL402
INSTALLATION402
DISASSEMBLY404
ASSEMBLY406
TRACK ROLLER410
REMOVAL410
INSTALLATION410
DISASSEMBLY411
ASSEMBLY412
CARRIER ROLLER414
REMOVAL414
INSTALLATION415
DISASSEMBLY416
ASSEMBLY417
TRACK SHOE 418
CHECKING BEFORE REMOVAL418
REMOVAL418
INSTALLATION420
OVERALL DISASSEMBLY424
OVERALL ASSEMBLY429
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS443
FIELD DISASSEMBLY OF ONE LINK444
FIELD ASSEMBLY OF ONE LINK445
PIVOT SHAFT452
REMOVAL452
INSTALLATION452
EQUALIZER BAR453
REMOVAL453
INSTALLATION454
EQUALIZER BAR SIDE BUSHING455
REMOVAL455
INSTALLATION455
SEGMENT TEETH456
REMOVAL456
INSTALLATION456
WORK EQUIPMENT PUMP457
REMOVAL457
INSTALLATION457
MAIN CONTROL VALVE458
REMOVAL458
INSTALLATION458
DISASSEMBLY459
ASSEMBLY461
SUCTION VALVE463
REMOVAL463
INSTALLATION463
BLADE LIFT CYLINDER465
REMOVAL465
INSTALLATION465
DISASSEMBLY466
ASSEMBLY468
BLADE470
REMOVAL470
INSTALLATION471
SWEEP, CANOPY472
REMOVAL472
INSTALLATION472
DASHBOARD473
REMOVAL473
INSTALLATION473
FLOOR FRAME474
REMOVAL474
INSTALLATION477
40 MAINTENANCE STANDARD478
ENGINE MOUNT479
POWER TRAIN UNIT MOUNT480
DAMPER, UNIVERSAL JOINT481
TORQUE CONVERTER, PTO482
TRANSMISSION484
TRANSMISSION CONTROL VALVE486
MAIN RELIEF VALVE488
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE489
STEERING CONTROL VALVE491
POWER TRAIN, LUBRICATION PUMP492
FINAL DRIVE493
HULL FRAME495
TRACK FRAME, RECOIL SPRING496
IDLER498
TRACK ROLLER499
CARRIER ROLLER500
TRACK SHOE 501
SUSPENSION505
HYDRAULIC PUMP509
MAIN CONTROL VALVE511
WORK EQUIPMENT CYLINDER513
WORK EQUIPMENT514
CUTTING EDGE, END BIT516
90 OTHERS517
1 GENERAL518
1-1 SPECIFICATION518
1-2 POWER TRAIN SYSTEM519
2 STRUCTURE AND FUNCTION520
2-1 GENERAL VIEW520
2-2 WINCH SECTION521
2-3 HYDRAULIC SYSTEM523
2-3-1 PIPING523
2-3-2 HYDRAULIC CIRCUIT DIAGRAM524
2-3-3 GENERAL VIEW OF CONTROL VALVE AND FUNCTION525
2-3-4 CLUTCH STRUCTURE AND FUNCTION (INCL LUBRICATION VALVE)526
2-4 CONTROL OF WINCH528
2-5 FAIRLEAD529
3 TESTING AND ADJUSTING530
3-1 STANDARD VALUE TABLE FOR TOWING WINCH530
3-2 TOOL LIST FOR TESTING AND ADJUSTING531
3-3 ADJUSTING TOWING WINCH CONTROL LEVER532
3-4 MEASURING AND ADJUSTING TOWING WINCH OIL PRESSURE533
3-5 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEMS)535
H-1 TOWING WINCH DOES NOT TURN536
H-2 TOWING WINCH BRAKE DOES NOT WORK537
4 DISASSEMBLY AND ASSEMBLY538
METHOD OF USING MANUAL538
PRECAUTIONS WHEN CARRYING OUT OPERATION539
4-1 SPECIAL TOOL LIST541
4-2 TOWING WINCH ASSEMBLY542
REMOVAL542
INSTALLATION542
4-3 TOWING WINCH PUMP ASSEMBLY543
REMOVAL543
INSTALLATION543
4-4 TOWING WINCH CONTROL VALVE ASSEMBLY544
REMOVAL544
INSTALLATION544
DISASSEMBLY545
ASSEMBLY547
4-5 TOWING WINCH ASSEMBLY549
DISASSEMBLY549
ASSEMBLY562
4-6 ASSEMBLING INFORMATION582
4-6-1 BEARING CLEARANCE AND GEAR BACKLASH582
5 MAINTENANCE STANDARD583
5-1 CLUTCH583
5-2 BRAKE584
5-3 VALVE585
5-4 TOWING WINCH PUMP587

IMAGES PREVIEW OF THE MANUAL:

S.M 22/12/24