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Komatsu D80A-18 D80E-18 D80P-18 D85A-18 D85E-18 D85P-18 Bulldozer Shop Manual SEBM0150C05
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Komatsu D80A-18 D80E-18 D80P-18 D85A-18 D85E-18 D85P-18 Bulldozer Shop Manual SEBM0150C05

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Komatsu D80A-18 D80E-18 D80P-18 D85A-18 D85E-18 D85P-18 Bulldozer Shop Manual SEBM0150C05 – PDF DOWNLOAD

MACHINE MODEL    SERIAL NO.
D80A-18                    25001 and up
D85A-18                    25001 and up
D80E-18                    25001 and up
D85E-18                    25001 and up
D80P-18                    2001 and up
D85P-18                    2001 and up

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Description

Komatsu D80A-18 D80E-18 D80P-18 D85A-18 D85E-18 D85P-18 Bulldozer Shop Manual SEBM0150C05 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D80A-18 D80E-18 D80P-18 D85A-18 D85E-18 D85P-18 Bulldozer Shop Manual SEBM0150C05 – PDF DOWNLOAD 

Language : English
Pages : 613
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D80A-18 D80E-18 D80P-18 D85A-18 D85E-18 D85P-18 Bulldozer Shop Manual SEBM0150C05 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NO.
D80A-18                    25001 and up
D85A-18                    25001 and up
D80E-18                    25001 and up
D85E-18                    25001 and up
D80P-18                    2001 and up
D85P-18                    2001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
● Always wear safety glasses when hitting parts with a hammer.
● Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.

PREPARATIONS FOR WORK:

7. Before adding oil or making repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

PRECAUTIONS DURING WORK :

11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out. Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned. Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. ALWAYS remove the lead from the negative (-) terminal first.

TABLE OF CONTENTS:

Komatsu D80A-18 D80E-18 D80P-18 D85A-18 D85E-18 D85P-18 Bulldozer Shop Manual SEBM0150C05 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NO.
D80A-18                    25001 and up
D85A-18                    25001 and up
D80E-18                    25001 and up
D85E-18                    25001 and up
D80P-18                    2001 and up
D85P-18                    2001 and up

COVER 1
CONTENTS 2
10 ENGINE 15
11 STRUCTURE AND FUNCTION 15
CONTENTS 16
GENERAL STRUCTURE 17
INTAKE AND EXHAUST SYSTEM 19
TURBOCHARGER 27
AFTER-COOLER 29
ENGINE BODY 30
CYLINDER HEAD 30
VALVE SYSTEM 31
CYLINDER BLOCK 33
MAIN CIRCULATION SYSTEM 35
TIMING GEAR 36
CAMSHAFT, CAM FOLLOWER AND PUSH ROD 37
INJECTION TIMING, VALVE TIMING 38
FLYWHEEL AND FLYWHEEL HOUSING 39
LUBRICATION SYSTEM 46
LUBRICATION SYSTEM CHART 46
OIL PUMP 48
OIL FILTER AND OIL COOLER 51
FULL-FLOW FILTER 54
BY-PASS FILTER 55
OIL COOLER 56
FUEL SYSTEM 57
FUEL SYSTEM CHART 57
PT FUEL PUMP 60
PT FUEL PUMP DRIVE 70
INJECTOR 72
FUEL FILTER 73
WATER SEPARATOR 75
ANEROID CONTROL VALVE 76
COOLING SYSTEM 77
COOLING SYSTEM CHART 77
WATER PUMP 79
FAN DRIVE 82
TENSION PULLEY 86
THERMOSTAT 88
CORROSION RESISTOR 89
ACCESSORY 90
AIR COMPRESSOR 90
ELECTRICAL SYSTEM 91
ALTERNATOR 91
STARTING MOTOR 94
ELECTRICAL INTAKE AIR HEATER 96
20 POWER TRAIN 98
21 STRUCTURE AND FUNCTION 98
STRUCTURE AND FUNCTION 99
GENERAL D80 100
GENERAL D85 102
MAIN CLUTCH D80 104
INERTIA BRAKE 108
MAIN CLUTCH HYDRAULIC BOOSTER 109
MAIN RELIEF VALVE 112
OIL COOLER LUBRICATION VALVE 112
MAIN CLUTCH PUMP 113
MAIN CLUTCH HYDRAULIC SYSTEM 114
MAIN CLUTCH HYDRAULIC CIRCUIT 114
TRANSMISSION 115
INTERLOCK 119
DOUBLE-MESH PREVENTIVE DEVICE 121
TRANSMISSION LUBRICATION VALVE 122
TORQUE CONVERTER 123
TORQUE CONVERTER RELIEF VALVE 126
TORQUE CONVERTER REGULATOR VALVE 126
SCAVENGING PUMP 126
TORQFLOW TRANSMISSION 127
POWER TRANSMISSION LINE 133
TRANSMISSION CONTROL VALVE 137
MODULATING RELIEF VALVE 138
REDUCING VALVE 141
SAFETY VALVE 142
TRANSMISSION LUBRICATION VALVE 143
TRANSMISSION PUMP 144
TRANSMISSION, STEERING OIL STRAINER 145
TRANSMISSION OIL FILTER 146
TORQFLOW HYDRAULIC SYSTEM 147
TORQFLOW HYDRAULIC CIRCUIT 148
BEVEL GEAR SHAFT STEERING CLUTCH 149
STEERING CONTROL VALVE 152
STEERING PUMP 157
STEERING OIL FILTER 158
STEERING HYDRAULIC CIRCUIT 159
STEERING HYDRAULIC SYSTEM 160
STEERING BRAKE 161
BRAKE BOOSTER VALVE 164
BRAKE HYDRAULIC SYSTEM 165
STEERING BRAKE HYDRAULIC CIRCUIT 166
FINAL DRIVE 167
STEERING AND MAIN CLUTCH HYDRAULIC PIPING D80 170
STEERING AND TORQFLOW HYDRAULIC PIPING D85 171
MAIN CLUTCH AND TRANSMISSION CONTROL D80 172
TORQFLOW TRANSMISSION CONTROL 173
STEERING CONTROL 174
22 TESTING AND ADJUSTING 176
INSPECTION AND ADJUSTMENT 177
GENERAL 178
OIL PRESSURE MEASURING POINTS (D80) 180
OUTLINE OF OIL PRESSURE AND TEMPERATURE MEASUREMENTS (D80) 181
TRAVEL MEASUREMENTS (D80) 184
OPERATING FORCE MEASUREMENTS (D80) 185
ADJUSTING MAIN CLUTCH AND INERTIA BRAKE (D80) 187
PROCEDURE FOR ADJUSTING STROKES 189
STANDARD VALUES (D80) 191
OIL PRESSURE MEASURING POINTS (D85) 195
OUTLINE OF OIL PRESSURE AND TEMPERATURE MEASUREMENTS (D85) 196
TRAVEL MEASUREMENTS (D85) 200
OPERATING FORCE MEASUREMENTS (D85) 200
STANDARD VALUES (D85) 202
23 DISASSEMBLY AND ASSEMBLY 206
DISASSEMBLY AND ASSEMBLY 207
DISMOUNTING MAIN CLUTCH ASSEMBLY (D80) 209
MOUNTING MAIN CLUTCH ASSEMBLY (D80) 214
DISASSEMBLY OF MAIN CLUTCH ASSEMBLY (D80) 219
ASSEMBLY OF MAIN CLUTCH ASSEMBLY (D80) 222
DISMOUNTING MAIN CLUTCH BOOSTER ASSEMBLY (D80) 227
MOUNTING MAIN CLUTCH BOOSTER ASSEMBLY (D80) 228
DISASSEMBLY OF MAIN CLUTCH BOOSTER ASSEMBLY (D80) 229
ASSEMBLY OF MAIN CLUTCH BOOSTER ASSEMBLY (D80) 230
DISMOUNTING TRANSMISSION ASSEMBLY (D80) 231
MOUNTING TRANSMISSION ASSEMBLY (D80) 235
DISASSEMBLY OF TRANSMISSION (D80) 239
ASSEMBLY OF TRANSMISSION (D80) 247
DISMOUNTING TORQUE CONVERTER ASSEMBLY (D85) 256
MOUNTING TORQUE CONVERTER ASSEMBLY (D85) 261
DISASSEMBLY OF TORQUE CONVERTER ASSEMBLY (D85) 266
ASSEMBLY OF TORQUE CONVERTER ASSEMBLY (D85) 274
DISMOUNTING TORQUE CONVERTER RELIEF VALVE ASSEMBLY 284
MOUNTING TORQUE CONVERTER RELIEF VALVE ASSEMBLY 284
DISMOUNTING TORQUE CONVERTER REGULATOR VALVE ASSEMBLY 285
MOUNTING TORQUE CONVERTER REGULATOR VALVE ASSEMBLY 285
DISMOUNTING TORQFLOW TRANSMISSION ASSEMBLY (D85) 286
MOUNTING TORQFLOW TRANSMISSION ASSEMBLY (D85) 294
DISASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY (D85) 302
ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY (D85) 319
DISMOUNTING TRANSMISSION CONTROL VALVE ASSEMBLY (D85) 338
MOUNTING TRANSMISSION CONTROL VALVE ASSEMBLY (D85) 338
DISASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY (D85) 339
ASSEMBLY OF TRANSMISSION CONTROL VALVE ASSEMBLY (D85) 342
DISMOUNTING TRANSMISSION LUBRICATION VALVE ASSEMBLY (D85) 345
MOUNTING TRANSMISSION LUBRICATION VALVE ASSEMBLY (D85) 345
DISMOUNTING MAIN CLUTCH PUMP (D80),TRANSMISSION PUMP (D85) ASSEMBLY 346
MOUNTING MAIN CLUTCH PUMP (D80),TRANSMISSION PUMP (D85) ASSEMBLY 346
DISMOUNTING STEERING PUMP ASSEMBLY 347
MOUNTING STEERING PUMP ASSEMBLY 347
DISMOUNTING BEVEL GEAR SHAFT AND BEVEL GEAR 348
MOUNTING BEVEL GEAR SHAFT AND BEVEL GEAR 351
DISMOUNTING STEERING CLUTCH ASSEMBLY 358
MOUNTING STEERING CLUTCH ASSEMBLY 362
DISASSEMBLY OF STEERING CLUTCH ASSEMBLY 367
ASSEMBLY OF STEERING CLUTCH ASSEMBLY 369
DISMOUNTING STEERING CONTROL VALVE ASSEMBLY 372
MOUNTING STEERING CONTROL VALVE ASSEMBLY 372
DISASSEMBLY OF STEERING CONTROL VALVE 373
DISASSEMBLY OF MAIN RELIEF VALVE 375
DISMOUNTING BRAKE SAFETY VALVE ASSEMBLY 378
MOUNTING BRAKE SAFETY VALVE ASSEMBLY 378
DISASSEMBLY OF BRAKE SAFETY VALVE 379
ASSEMBLY OF BRAKE SAFETY VALVE 379
DISASSEMBLY OF BRAKE BOOSTER 380
ASSEMBLY OF BRAKE BOOSTER 380
DISASSEMBLY OF FINAL DRIVE ASSEMBLY 381
ASSEMBLY OF FINAL DRIVE ASSEMBLY 388
DISMOUNTING FLOOR FRAME ASSEMBLY 395
MOUNTING FLOOR FRAME ASSEMBLY (D80) 399
DISMOUNTING FLOOR FRAME ASSEMBLY (D85) 403
MOUNTING FLOOR FRAME ASSEMBLY (D85) 406
24 MAINTENANCE STANDARD 409
MAINTENANCE STANDARD 410
MAIN CLUTCH D80 411
(1) PLATE, GEAR, SHAFT 411
(2) INERTIA BRAKE 413
(3) MAIN CLUTCH BOOSTER 414
TRANSMISSION D80 415
(1) TRANSMISSION CASE, GEAR 415
(2) GEAR SHIFT LEVER CASE 417
TORQUE CONVERTER D85 419
(1) TORQUE CONVERTER 419
(2) RELIEF VALVE AND REGULATOR VALVE 421
TORQFLOW TRANSMISSION D85 422
(1) TRANSMISSION 422
(2) CONTROL VALVE 425
BEVEL GEAR SHAFT AND STEERING CLUTCH 427
(1)BEVEL GEAR SHAFT 427
(2)STEERING CLUTCH 429
(3)STEERING BRAKE 431
(4)STEERING CONTROL VALVE 432
(5)STEERING BRAKE VALVE AND BOOSTER 433
FINAL DRIVE 434
30 UNDER CARRIAGE 437
31 STRUCTURE AND FUNCTION 437
STRUCTURE AND FUNCTION 438
TRACK GROUP 439
RECOIL SPRING 441
IDLER 442
TRACK ROLLER 443
CARRIER ROLLER 444
TRACK 445
SUSPENSION 449
33 DISASSEMBLY AND ASSEMBLY 451
DISASSEMBLY AND ASSEMBLY 452
DISMOUNTING TRACK FRAME ASSEMBLY 453
MOUNTING TRACK FRAME ASSEMBLY 455
DISMOUNTING RECOIL SPRING ASSEMBLY 457
MOUNTING RECOIL SPRING ASSEMBLY 460
DISASSEMBLY OF RECOIL SPRING ASSEMBLY 464
ASSEMBLY OF RECOIL SPRING ASSEMBLY 466
DISMOUNTING IDLER ASSEMBLY 468
MOUNTING IDLER ASSEMBLY 469
DISMOUNTING TRACK ROLLER ASSEMBLY 470
MOUNTING TRACK ROLLER ASSEMBLY 471
DISMOUNTING CARRIER ROLLER ASSEMBLY 472
MOUNTING CARRIER ROLLER ASSEMBLY 472
SEPARATION OF TRACK 473
CONNECTION OF TRACK 474
34 MAINTENANCE STANDARD 475
MAINTENANCE STANDARD 476
UNDERCARRIAGE 477
(1)TRACK FRAME D80,85A 477
(1)TRACK FRAME D80,85P 478
(2)RECOIL SPRING 479
(3)IDLER 480
(4)TRACK ROLLER 482
(5)CARRIER ROLLER 484
(6)TRACK (SHOE) D80,85A 485
(6)TRACK (MASTER LINK TYPE) D80,85A,E 487
(6)TRACK (SHOE) D80,85P 489
(6)TRACK (MASTER LINK TYPE) D80,85P 491
60 HYDRAULIC CONTROL 493
61 STRUCTURE AND FUNCTION 493
STRUCTURE AND FUNCTION 494
HYDRAULIC PUMP 495
HYDRAULIC TANK 496
HYDRAULIC CONTROL VALVE 497
HYDRAULIC CYLINDER 502
QUICK DROP VALVE 507
WORK EQUIPMENT HYDRAULIC SYSTEM 508
WORK EQUIPMENT HYDRAULIC CIRCUIT 509
ROTARY SERVO VALVE 510
SERVO VALVE HYDRAULIC SYSTEM 514
SERVO VALVE HYDRAULIC CIRCUIT 514
WORK EQUIPMENT HYDRAULIC PIPING (PUMP–TANK) 515
WORK EQUIPMENT HYDRAULIC PIPING (BLADE LIFT) 516
WORK EQUIPMENT HYDRAULIC PIPING (BLADE TILT) 517
WORK EQUIPMENT HYDRAULIC PIPING (RIPPER) D80,85A 518
SERVO VALVE HYDRAULIC PIPING 519
WORK EQUIPMENT CONTROL 520
62 INSPECTION AND ADJUSTMENT 522
INSPECTION AND ADJUSTMENT 523
GENERAL 524
OIL PRESSURE MEASURING POINTS 525
OUTLINE OF OIL PRESSURE AND TEMPERATURE MEASUREMENTS 526
OIL FLOW MEASUREMENTS 528
MEASUREMENT OF OPERATING FORCE 529
STANDARD VALUES 530
63 DISASSEMBLY AND ASSEMBLY 533
DISASSEMBLY AND ASSEMBLY 534
DISMOUNTING HYDRAULIC PUMP ASSEMBLY 535
MOUNTING HYDRAULIC PUMP ASSEMBLY 535
DISMOUNTING BLADE CONTROL VALVE ASSEMBLY 536
MOUNTING BLADE CONTROL VALVE ASSEMBLY 538
DISASSEMBLY OF BLADE CONTROL VALVE ASSEMBLY 540
ASSEMBLY OF BLADE CONTROL VALVE ASSEMBLY 541
DISMOUNTING RIPPER CONTROL VALVE ASSEMBLY 542
MOUNTING RIPPER CONTROL VALVE ASSEMBLY 545
DISASSEMBLY OF RIPPER CONTROL VALVE ASSEMBLY 548
ASSEMBLY OF RIPPER CONTROL VALVE ASSEMBLY 548
DISMOUNTING BLADE LIFT SERVO VALVE ASSEMBLY 549
MOUNTING BLADE LIFT SERVO VALVE ASSEMBLY 549
DISMOUNTING BLADE TILT SERVO VALVE ASSEMBLY 550
MOUNTING BLADE TILT SERVO VALVE ASSEMBLY 550
DISMOUNTING RIPPER SERVO VALVE ASSEMBLY 551
MOUNTING RIPPER SERVO VALVE ASSEMBLY 551
DISMOUNTING BLADE LIFT CYLINDER ASSEMBLY 552
MOUNTING BLADE LIFT CYLINDER ASSEMBLY 552
DISMOUNTING BLADE TILT CYLINDER ASSEMBLY 553
MOUNTING BLADE TILT CYLINDER ASSEMBLY 553
DISMOUNTING RIPPER CYLINDER ASSEMBLY 554
MOUNTING RIPPER CYLINDER ASSEMBLY 554
DISASSEMBLY OF CYLINDER ASSEMBLY 555
ASSEMBLY OF CYLINDER ASSEMBLY 558
64 MAINTENANCE STANDARD 561
MAINTENANCE STANDARD 562
WORK EQUIPMENT CONTROL VALVE 563
(1)BLADE LIFT AND TILT VALVE 563
(2)RIPPER VALVE D80,85A-18 565
(3)MAIN RELIEF, SUCTION AND SAFETY VALVE 567
WORK EQUIPMENT CYLINDER 568
(1)BLADE LIFT CYLINDER 568
(2)BLADE TILT CYLINDER 569
(3)RIPPER CYLINDER D80,85A 570
QUICK DROP VALVE 571
ROTARY SERVO VALVE 572
70 WORK EQUIPMENT 573
71 STRUCTURE AND FUNCTION 573
STRUCTURE AND FUNCTION 574
STRAIGHT TILTDOZER D80,85A 575
STRAIGHT TILTDOZER D80,85P 577
FIXED MULTI-SHANK RIPPER D80,85A 579
73 DISASSEMBLY AND ASSEMBLY 581
DISASSEMBLY AND ASSEMBLY 582
DISMOUNTING BLADE ASSEMBLY 583
MOUNTING BLADE ASSEMBLY 583
DISASSEMBLY OF BLADE ASSEMBLY 584
ASSEMBLY OF BLADE ASSEMBLY 587
DISASSEMBLY OF RIPPER ASSEMBLY 591
ASSEMBLY OF RIPPER ASSEMBLY 594
74 MAINTENANCE STANDARD 597
MAINTENANCE STANDARD 598
STRAIGHT TILTDOZER D80,85A 599
STRAIGHT TILTDOZER D80,85P 601
CYLINDER STAY D80,85A 604
CYLINDER STAY D80,85P 604
FIXED MULTI-SHANK RIPPER D80,85A 605
90 OTHERS 606
ELECTRICAL SYSTEM 607
ELECTRICAL CIRCUIT 608
WIRING DIAGRAM 612

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