Komatsu BULLDOZER D85ESS-3 Shop Manual SEN06496-01 PDF

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Komatsu BULLDOZER D85ESS-3 Shop Manual SEN06496-01 – PDF DOWNLOAD

FILE DETAILS:

Komatsu BULLDOZER D85ESS-3 Shop Manual SEN06496-01 – PDF DOWNLOAD

Language : English
Pages :1032
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu BULLDOZER D85ESS-3 Shop Manual SEN06496-01 – PDF DOWNLOAD

SERIAL NUMBERS 10001 and up

1. General precautions 

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work.

TABLE OF CONTENTS:

Komatsu BULLDOZER D85ESS-3 Shop Manual SEN06496-01 – PDF DOWNLOAD

SERIAL NUMBERS 10001 and up

Cover 1
00 Index and foreword 3
Table of contents 4
Foreword and general information 13
Safety notice 13
How to read the shop manual 18
Explanation of terms for maintenance standard 20
Handling of electric equipment and hydraulic components 22
Handling of connectors newly used for engines 31
How to read electric wire code 34
Precautions when carrying out work 37
Method of disassembling and connecting push-pull type coupler 40
Standard tightening torque table 43
List of Abbreviation 47
Conversion table 51
01 Specification 57
Specification 59
Specification drawing 59
Weight table 64
Table of fuel, coolant, and lubricants 66
10 Structure and function 69
Engine and cooling system 72
Damper 72
Cooling system 74
Cooling fan pump 76
Servo valve 82
Self-pressure reducing valve 85
Cooling fan motor 92
Reversible valve 97
Safety valve 99
Power train 101
Power train 101
Overall drawing of power train unit 103
Hydraulic piping drawing of power train 104
Transmission, steering, and brake control 105
Universal joint 106
Torque converter and PTO 107
Transmission 111
Transmission control valve 118
Main relief valve 123
Lubrication relief valve 125
Bevel gear shaft, steering clutch, steering brake 127
Steering brake valve 134
Reducing valve 138
Scavenging pump strainer 139
Power train oil strainer 140
Final drive 142
Power transmitting route 144
Undercarriage and frame 146
Main frame 146
Suspension 148
Track frame 150
Recoil spring 151
Hydraulic system 152
Hydraulic component layout 152
Angle dozer 152
Straight tilt dozer 153
Ripper 154
Work equipment control 156
Hydraulic tank 158
Breather 160
Work equipment pump 161
Steering lubrication pump and power train pump 162
Scavenging pump 163
Control valve 164
Steering PPC valve 186
Blade PPC valve 190
Ripper PPC valve 196
Quick drop valve 199
PPC lock valve 201
Hydraulic oil cooler bypass valve 202
PPC circuit accumulator 203
Work equipment 204
Angle dozer 204
Straight tilt dozer 205
Ripper 206
Piston valve 207
Floor frame and its attachments 208
Floor mount 208
Electrical system 209
Engine control 209
Engine control system 210
Cooling system control system 212
Machine monitor system 214
KOMTRAX system 223
KOMTRAX terminal 224
System component parts 227
Power train controller 231
Sensors 238
20 Standard value table 243
Standard value table for engine 245
Standard value table for machine 246
30 Testing and adjusting 253
Related information on testing and adjusting 256
Tools for testing, adjusting, and troubleshooting 256
Engine and cooling system 259
Testing engine speed 259
Testing intake air pressure (boost pressure) 261
Testing exhaust gas temperature 263
Testing exhaust gas color 265
Adjusting valve clearance 266
Testing compression pressure 268
Testing blowby pressure 272
Testing engine oil pressure 273
Handling equipment of fuel system devices 274
Releasing remaining pressure from fuel system 274
Testing fuel pressure 275
Testing fuel return rate and leakage 280
Bleeding air from fuel circuit 282
Testing fuel circuit for leakage 283
Handling cylinder cutout mode operation 284
Handling no-injection cranking operation 284
Replacing alternator belt 285
Adjusting fuel control linkage 286
Adjusting decelerator pedal 287
Handling engine controller high voltage circuit 289
Power train 290
Measuring power train oil pressure 290
Procedure for simple test of steering brake performance 294
Adjusting brake pedal linkage 295
Adjusting steering and directional lever, gear shift lever, parking brake lever linkage 296
Hydraulic system 300
Testing and adjusting work equipment hydraulic pressure 300
Testing and adjusting control circuit pressure 301
Measuring output pressure of PPC valve 302
Testing and adjusting play of work equipment PPC valve 303
Testing internal oil leakage of work equipment cylinder 305
Bleeding air from work equipment cylinders 306
Releasing remaining pressure in work equipment cylinder 306
Isolating parts that cause hydraulic drift of blade and ripper 307
Testing fan speed 308
Testing fan circuit oil pressure 309
Bleeding air from fan pump 310
Work equipment 311
Adjusting straight tilt dozer 311
Adjusting work equipment lock lever 313
Procedure for testing sensors 314
Electrical system 315
Special functions of machine monitor 315
How to start operation of KOMTRAX terminal 338
Handling voltage circuit of engine controller 341
Adjustment method when controller is replaced 342
Preparation for troubleshooting of electrical system 344
Testing diodes 348
Pm Clinic 350
Pm Clinic service 350
40 Troubleshooting 359
General information on troubleshooting 365
Points to remember when troubleshooting 365
Sequence of events in troubleshooting 366
Checks before troubleshooting 368
Inspection procedure before troubleshooting 370
Preparation for troubleshooting of the electrical system 376
Classification and procedures of troubleshooting 380
Symptoms and troubleshooting Nos 381
Information described in the failure code list 383
Troubleshooting method for disconnecting wiring harness of pressure sensor system 385
Connector list and layout 387
Connection table for connector pin numbers 396
T- branch box and T- branch adapter table 432
Fuse location table 435
Troubleshooting by failure code (code display) 437
Failure codes table 437
Failure code [AB00MA] Battery Charge Abnormal 442
Failure code [B@BAZG] Eng Oil Press Low 444
Failure code [B@BCNS] Eng Water Overheat 444
Failure code [B@CENS] T/C Oil Overheat 445
Failure code [B@HANS] Hyd Oil Overheat 445
Failure code [CA111] ECM Critical Internal Failure 446
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 447
Failure code [CA122] Chg Air Press Sensor High Error 448
Failure code [CA123] Chg Air Press Sensor Low Error 450
Failure code [CA131] Throttle Sensor High Error 452
Failure code [CA132] Throttle Sensor Low Error 454
Failure code [CA144] Coolant Temp Sens High Error 456
Failure code [CA145] Coolant Temp Sens Low Error 458
Failure code [CA153] Chg Air Temp Sensor High Error 460
Failure code [CA154] Chg Air Temp Sensor Low Error 462
Failure code [CA155] Chg Air Temp High Speed Derate 464
Failure code [CA187] Sens Supply 2 Volt Low Error 466
Failure code [CA221] Ambient Press Sens High Error 468
Failure code [CA222] Ambient Press Sens Low Error 470
Failure code [CA227] Sens Supply 2 Volt High Error 472
Failure code [CA234] Eng Overspeed 472
Failure code [CA238] Ne Speed Sens Supply Volt Error 473
Failure code [CA271] IMV/PCV1 Short Error 474
Failure code [CA272] IMV/PCV1 Open Error 476
Failure code [CA281] Abnormal supply pump pressure balance 478
Failure code [CA322] Inj #1(L#1) Open/Short Error 480
Failure code [CA323] Inj #5(L#5) Open/Short Error 482
Failure code [CA324] Inj #3(L#3) Open/Short Error 484
Failure code [CA325] Inj #6(L#6) Open/Short Error 486
Failure code [CA331] Inj #2(L#2) Open/Short Error 488
Failure code [CA332] Inj #4(L#4) Open/Short Error 490
Failure code [CA342] Calibration Code Incompatibility 492
Failure code [CA351] Injectors Drive Circuit Error 493
Failure code [CA352] Sens Supply 1 Volt Low Error 494
Failure code [CA386] Sens Supply 1 Volt High Error 496
Failure code [CA428] Water in Fuel Sensor High Error 498
Failure code [CA429] Water in Fuel Sensor Low Error 500
Failure code [CA435] Eng Oil Press Sw Error 502
Failure code [CA441] Battery Voltage Low Error 504
Failure code [CA442] Battery Voltage High Error 506
Failure code [CA449] Rail Press Very High Error 508
Failure code [CA451] Rail Press Sensor High Error 510
Failure code [CA452] Rail Press Sensor Low Error 512
Failure code [CA488] Chg Air Temp High Torque Derate 514
Failure code [CA553] Rail Press High Error 515
Failure code [CA559] Rail Press Low Error 516
Failure code [CA689] Eng Ne Speed Sensor Error 518
Failure code [CA731] Eng Bkup Speed Sens Phase Error 522
Failure code [CA757] All Continuous Data Lost Error 523
Failure code [CA778] Eng Bkup Speed Sensor Error 524
Failure code [CA1633] KOMNET Datalink Timeout Error 527
Failure code [CA2185] Throt Sens Sup Volt High Error 528
Failure code [CA2186] Throt Sens Sup Volt Low Error 530
Failure code [CA2249] Rail Press Very Low Error 532
Failure code [CA2265] Fuel Feed Pump Open Error 534
Failure code [CA2266] Fuel Feed Pump Short Error 536
Failure code [CA2311] IMV Solenoid Error 537
Failure code [CA2555] Grid Htr Relay Volt High Error 538
Failure code [CA2556] Grid Htr Relay Volt Low Error 540
Failure code [D130KA] Neutral relay: Open, hot short 542
Failure code [D130KB] Neutral relay: Short circuit 544
Failure code [DAFRKR] CAN Open Circuit (Monitor) 546
Failure code [DAFRMC] CAN Discon (Monitor Detected) 550
Failure code [DB2RKR] CAN Open Circuit (Engine Con) 555
Failure code [DBE0KT] Abnormality in Non-volatile Memory 560
Failure code [DBE0MC] PT Con Error 561
Failure code [DBE1KK] Controller Power Source Low 562
Failure code [DBE2KK] Solenoid Power Source Low 564
Failure code [DBE5KK] Sensor volt 5V (0) Out of normal range 566
Failure code [DD14KA] Parking lever Sw: Open 568
Failure code [DD14KB] Parking lever Sw: Ground fault, Short circuit 570
Failure code [DGS1KA] Failure of Hyd oil temp sensor 572
Failure code [DGS1KX] Hyd oil temp: Ground Fault 574
Failure code [DGT1KA] T/C oil temp sensor Failure 576
Failure code [DGT1KX] T/C oil temp sensor: Ground fault 578
Failure code [DK10KA] Fuel control Dial: Out of normal range 580
Failure code [DK10KB] Fuel control Dial: Out of normal range 582
Failure code [DLM3KA] Fan rev sensor: Open 584
Failure code [DLM3MB] Fan control: Mismatch 585
Failure code [DNCEKA] 1st limit switch open circuit 586
Failure code [DNCEKB] 1st limit switch short circuit 588
Failure code [DNCGKA] 3rd limit switch open circuit 590
Failure code [DNCGKB] 3rd limit switch short circuit 591
Failure code [DV00KB] Alarm buzzer: Short circuit 592
Failure code [DW7BKA] Fan reverse solenoid: Open 594
Failure code [DW7BKB] Fan reverse solenoid: Short circuit 595
Failure code [DW7BKY] Fan reverse solenoid: Hot short 596
Failure code [DWN5KA] Fan pump solenoid: Open 597
Failure code [DWN5KB] Fan pump solenoid: Short circuit 598
Failure code [DWN5KY] Fan pump solenoid: Hot Short 599
Troubleshooting for the electrical system (E-mode) 601
Before carrying out troubleshooting for the electrical system 601
Information in troubleshooting table 602
E-1 Engine does not start (starting motor does not revolve) 603
E-2 Preheating system does not operate 606
E-3 When the starting switch is turned to the ON position, nothing is displayed on the machine monitor 610
E-4 When the starting switch is turned to the ON position (while the engine is stopped), the basic check item monitor lights up 613
E-5 Caution item monitor lights up when the engine is running 614
E-6 Engine coolant temperature monitor lights up red when the engine is running 616
E-7 Engine oil pressure monitor lights up red when the engine is running 617
E-8 Power train oil temperature monitor lights up red when the engine is running 618
E-9 Hydraulic oil temperature monitor lights up red when the engine is running 619
E-10 Engine coolant temperature gauge does not indicate the correct temperature 620
E-11 Fuel level gauge does not indicate the correct level 622
E-12 Power train oil temperature gauge does not indicate the correct temperature 625
E-13 Hydraulic oil temperature gauge does not indicate the correct temperature 626
E-14 Operation mode does not change 627
E-15 Alarm buzzer does not sound or does not stop sounding 628
E-16 Service meter is not displayed when the starting switch is in OFF position 630
E-17 Buzzer cancel switch does not work 632
E-18 Information switch does not work 634
E-19 Service mode cannot be selected 636
E-20 Horn does not sound or does not stop sounding 638
E-21 Backup alarm does not sound or does not stop sounding 640
E-22 Headlamp and rear lamp do not light up 643
E-23 KOMTRAX system does not operate normally 646
Troubleshooting for hydraulic and mechanical system (H-mode) 648
Table of failure modes and causes 648
Information described in troubleshooting table 650
H-1 Machine lacks power (insufficient drawbar pull) 651
H-2 Machine does not travel (at 2nd or 3rd gear speed) 653
H-3 Machine cannot star at any gear speed 655
H-4 Machine travels only in one direction, either forward or in reverse 657
H-5 Large time lag is in gear shifting or directional change 658
H-6 Machine cannot be steered (machine does not turn left or right) 659
H-7 Machine turns dully 659
H-8 Machine turns only in one direction (when controlled by using steering and directional lever) 659
H-9 Brake does not work 660
H-10 Power train oil overheats 661
H-11 Unusual noise is heard from around work equipment pump 662
H-12 All work equipment lack speed 662
H-13 All work equipment do not operate 663
H-14 All work equipment lack power 664
H-15 Blade lift speed or power is low 665
H-16 Blade tilt speed or power is low 665
H-17 Ripper lift speed or power is low 666
H-18 Hydraulic drift of lifted blade is large 666
H-19 Hydraulic drift of tilted blade is large 667
H-20 Hydraulic drift of lifted ripper is large 667
Troubleshooting of engine (S-mode) 669
Method of using troubleshooting charts 669
S-1 Starting performance is poor 672
S-2 Engine does not start 674
S-3 Engine does not pick up smoothly 677
S-4 Engine stops during operations 678
S-5 Engine does not rotate smoothly 679
S-6 Engine lacks output (or lacks power) 680
S-7 Exhaust smoke is black (incomplete combustion) 681
S-8 Oil consumption is excessive (or exhaust smoke is blue) 682
S-9 Oil becomes contaminated quickly 683
S-10 Fuel consumption is excessive 684
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 685
S-12 Oil pressure drops 686
S-13 Oil level rises (water, fuel in oil) 687
S-14 Coolant temperature becomes too high (overheating) 688
S-15 Abnormal noise is made 689
S-16 Vibration is excessive 690
Shop Manual 691
50 Disassembly and assembly 691
Related information on disassembly and assembly 694
How to read this manual 694
Coating materials list 696
Special tools list 700
Engine and cooling system 701
Removal and installation of fuel supply pump assembly 701
Removal and installation of fuel injector assembly 705
Removal and installation of cylinder head assembly 715
Removal and installation of radiator assembly 730
Removal and installation of aftercooler assembly 733
Removal and installation of hydraulic oil cooler assembly 735
Removal and installation of power train oil cooler assembly 738
Removal and installation of cooling fan drive assembly 741
Removal and installation of cooling fan motor assembly 743
Removal and installation of engine assembly 745
Disassembly and assembly of damper assembly 751
Removal and installation of engine front oil seal 754
Removal and installation of engine rear oil seal 758
Removal and installation of engine hood assembly 766
Removal and installation of fuel tank assembly 768
Power train 770
Removal and installation of power train unit assembly 770
Separation and connection of power train unit 773
Disassembly and assembly of torque converter assembly 776
Disassembly and assembly of PTO assembly 781
Disassembly and assembly of TORQFLOW transmission assembly 786
Disassembly and assembly of steering case assembly 804
Removal and installation of torque converter valve assembly 817
Disassembly and assembly of torque converter valve assembly 818
Removal and installation of transmission control valve assembly 819
Disassembly and assembly of transmission control valve assembly 820
Removal and installation of brake valve assembly 822
Disassembly and assembly of brake valve assembly 823
Removal and installation of reducing valve assembly 826
Disassembly and assembly of reducing valve assembly 827
Removal and installation of scavenging pump assembly 828
Removal and installation of power train pump assembly 829
Removal and installation of final drive assembly 830
Disassembly and assembly of final drive assembly 832
Undercarriage and frame 839
Removal and installation of track frame assembly 839
Removal and installation of recoil spring assembly 841
Disassembly and assembly of recoil spring assembly 842
Removal and installation of idler assembly 845
Disassembly and assembly of idler assembly 846
Removal and installation of track roller assembly 851
Disassembly and assembly of track roller assembly 852
Removal and installation of roller assembly 855
Disassembly and assembly of carrier roller assembly 856
Removal and installation of track shoe assembly 858
Overall disassembly and assembly of track shoe 861
Press-fitting jig dimension table for link press 877
Field disassembly and assembly of one link 878
Removal and installation of pivot shaft assembly 884
Removal and installation of equalizer bar assembly 885
Removal and installation of equalizer bar side bushing 887
Removal and installation of segment teeth 888
Hydraulic system 889
Removal and installation of work equipment pump assembly 889
Removal and installation of cooling fan pump assembly 890
Removal and installation of main control valve assembly 892
Disassembly and assembly of main control valve assembly 894
Disassembly and assembly of ripper valve assembly 898
Removal and installation of main relief valve 901
Removal and installation of PPC valve assembly 902
Disassembly and assembly of PPC valve assembly 903
Removal and installation of suction valve assembly 905
Removal and installation of blade lift cylinder assembly 906
Angledozer 906
Straight tilt dozer, semi U-dozer 907
Removal and installation of blade tilt cylinder assembly 908
Disassembly and assembly of hydraulic cylinder assembly 909
Work equipment 914
Removal and installation of blade assembly 914
Angledozer 914
Straight tilt dozer, semi U-dozer 915
Disassembly and assembly of blade assembly 917
Floor frame and its attachments 921
Removal and installation of dashboard assembly 921
Removal and installation of floor frame assembly 922
Electrical system 926
Removal and installation of monitor panel assembly 926
Removal and installation of engine controller assembly 927
Removal and installation of power train controller assembly 929
Removal and installation of KOMTRAX terminal assembly 931
60 Maintenance standard 933
Engine and cooling system 935
Engine mount 935
Damper 936
Cooling system 938
Cooling fan pump 940
Cooling fan motor 944
Power train 946
Power train mount 946
Universal joint 947
Torque converter and PTO 948
Transmission 950
Transmission control valve 952
Main relief valve 953
Bevel gear shaft, steering clutch, and steering brake 954
Steering brake valve 956
Final drive 958
Sprocket 960
Undercarriage and frame 962
Main frame 962
Suspension 964
Track frame and recoil spring 966
Idler 967
Track roller 968
Carrier roller 970
Track shoe 972
Hydraulic system 976
Work equipment pump 976
Power train and lubrication pump 977
Scavenging pump 978
Control valve 980
Steering PPC valve 987
Blade PPC valve 990
Ripper PPC valve 992
Quick drop valve 993
Work equipment 994
Work equipment 994
Cutting edge and end bit 998
Ripper 999
Lift cylinder1000
Tilt cylinder1001
Ripper cylinder1002
Floor frame and its attachments1003
Floor mount1003
90 Diagrams and drawings1005
Hydraulic diagrams and drawings1007
Symbols used in hydraulic circuit diagrams1007
Power train hydraulic circuit diagram1009
Hydraulic circuit diagram1011
Electrical diagrams and drawings1015
Symbols used in electric circuit diagrams1015
Electrical circuit diagram 1019
Index1027

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S.M 26/12/24