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Komatsu D80A,E,P-18 D85A,E,P-18 Service Repair Manual SEBM0150C053 – PDF DOWNLOAD
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Komatsu D80A,E,P-18 D85A,E,P-18 Service Repair Manual
MACHINE MODEL SERIAL NO.
DB0A-18 25001 and up
D85A-18 25001 and up
D80E-18 25001 and up
D85E-18 25001 and up
DB0P-18 2001 and up
D85P-18 2001 and up
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Description
Komatsu D80A,E,P-18 D85A,E,P-18 Service Repair Manual
FILE DETAILS:
Komatsu D80A,E,P-18 D85A,E,P-18 Service Repair Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D80A-18, D80E-18, D80P-18, D85A-18, D85E-18, D85P-18
Serial Number: 25001 and up, 2001 and up
Book Code: SEBM0150C05
Language: English
Pages: 613
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D80A,E,P-18 D85A,E,P-18 Service Repair Manual
FOREWORD:
GENERAL:
- This shop manual has been prepared as an aid to improve the quality of repairs by giving the servicemen an accurate understanding of the product and by showing him the correct way to perform repairs and make iudgements. 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 further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs. as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating ‘Problems’ to “Causes” are also included In this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD:
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu D80A,E,P-18 D85A,E,P-18 Service Repair Manual
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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