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Komatsu D85A-21, D85E-21, D85P-21 35001 and up, 3001 and up Bulldozer Shop Manual SEBM01542110 – PDF DOWNLOAD
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Description
Komatsu D85A-21, D85E-21, D85P-21 35001 and up, 3001 and up Bulldozer Shop Manual SEBM01542110
FILE DETAILS:
Komatsu D85A-21, D85E-21, D85P-21 35001 and up, 3001 and up Bulldozer Shop Manual SEBM01542110
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D85A-21, D85E-21, D85P-21
Serial Number: 35001 and up, 3001 and up
Book Code: SEBM01542110
Language: English
Pages: 676
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D85A-21, D85E-21, D85P-21 35001 and up, 3001 and up Bulldozer Shop Manual SEBM01542110
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 judgements. 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 D85A-21, D85E-21, D85P-21 35001 and up, 3001 and up Bulldozer Shop Manual SEBM01542110
MAIN MENU....................................................................................................................................................................... 0 CONTENTS........................................................................................................................................................................ 2 01 GENERAL...................................................................................................................................................................... 23 SPECIFICATION DRAWING....................................................................................................................................................... 24 SPECIFICATIONS.............................................................................................................................................................. 28 WEIGHT TABLE................................................................................................................................................................ 40 TABLE OF FUEL, COOLANT AND LUBRICANTS....................................................................................................................................... 46 10 ENGINE....................................................................................................................................................................... 49 12 TESTING AND ADJUSTING.................................................................................................................................................... 49 STANDARDS FOR TESTING AND ADJUSTING .................................................................................................................................... 50 TESTING AND ADJUSTING TOOL LIST ........................................................................................................................................ 53 ADJUSTING VALVE CLEARANCE .............................................................................................................................................. 56 MEASURING COMPRESSION PRESSURE.......................................................................................................................................... 59 TESTING AND ADJUSTING FUEL INJECTION TIMING............................................................................................................................. 62 MEASURING BLOW-BY ..................................................................................................................................................... 65 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) ......................................................................................................................... 66 MEASURING EXHAUST COLOR ................................................................................................................................................ 67 MEASURING EXHAUST TEMPERATURE........................................................................................................................................... 68 MEASURING ENGINE OIL PRESSURE........................................................................................................................................... 69 MEASURING ENGINE SPEED ................................................................................................................................................. 69 TESTING AND ADJUSTING ALTERNATOR BELT TENSION........................................................................................................................... 70 TROUBLESHOOTING ........................................................................................................................................................ 71 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................................................................. 72 S-1 Starting performance is poor (starting always takes time) ...................................................................................................... 76 S-2 Engine does not start .......................................................................................................................................... 77 S-3 Engine does not pick up smoothly (follow-up is poor) ........................................................................................................... 80 S-4 Engine stops during operations ................................................................................................................................. 81 S-5 Engine does not rotate smoothly (hunting) ...................................................................................................................... 82 S-6 Engine lacks output (no power) ................................................................................................................................. 83 S-7 Exhaust smoke is black (incomplete combustion) ................................................................................................................. 84 S-8 Oil consumption is excessive (or exhaust smoke is blue) ........................................................................................................ 85 S-9 Oil becomes contaminated quickly ............................................................................................................................... 86 S-10 Fuel consumption is excessive ................................................................................................................................. 87 S-11 Oil is in cooling water, or water spurts back, or water level goes down ...................................................................................... 88 S-12 Oil pressure caution lamp lights up (drop in oil pressure) .................................................................................................... 89 S-13 Oil level rises (water, fuel in oil) .......................................................................................................................... 90 S-14 Water temperature becomes too high (overheating) .............................................................................................................. 91 S-15 Abnormal noise is made ........................................................................................................................................ 92 S-16 Vibration is excessive ........................................................................................................................................ 93 13 DISASSEMBLY AND ASSEMBLY................................................................................................................................................. 95 METHOD OF USING MANUAL.................................................................................................................................................. 98 PRECAUTIONS WHEN CARRYING OUT OPERATION................................................................................................................................. 99 SPECIAL TOOL LIST.......................................................................................................................................................101 D85A, E-21 Serial No. 36534 and up..................................................................................................................................101 D85P-21 Serial No. 3689 and up......................................................................................................................................101 STARTING MOTOR..........................................................................................................................................................102 REMOVAL.............................................................................................................................................................102 INSTALLATION........................................................................................................................................................102 ALTERNATOR..............................................................................................................................................................102 REMOVAL.............................................................................................................................................................102 INSTALLATION........................................................................................................................................................102 AIR COMPRESSOR..........................................................................................................................................................102 REMOVAL.............................................................................................................................................................102 INSTALLATION........................................................................................................................................................102 NOZZLE HOLDER...........................................................................................................................................................104 REMOVAL.............................................................................................................................................................104 INSTALLATION .......................................................................................................................................................104 FUEL INJECTION PUMP.....................................................................................................................................................104 REMOVAL.............................................................................................................................................................104 INSTALLATION .......................................................................................................................................................104 ENGINE OIL COOLER ......................................................................................................................................................106 REMOVAL.............................................................................................................................................................106 INSTALLATION........................................................................................................................................................106 THERMOSTAT .............................................................................................................................................................106 REMOVAL.............................................................................................................................................................106 INSTALLATION........................................................................................................................................................106 WATER PUMP..............................................................................................................................................................106 REMOVAL.............................................................................................................................................................106 INSTALLATION .......................................................................................................................................................106 TURBOCHARGER............................................................................................................................................................108 REMOVAL.............................................................................................................................................................108 INSTALLATION........................................................................................................................................................108 CYLINDER HEAD ..........................................................................................................................................................110 REMOVAL.............................................................................................................................................................110 INSTALLATION........................................................................................................................................................114 RADIATOR GUARD..........................................................................................................................................................120 REMOVAL.............................................................................................................................................................120 INSTALLATION........................................................................................................................................................120 RADIATOR ...............................................................................................................................................................122 REMOVAL.............................................................................................................................................................122 INSTALLATION........................................................................................................................................................122 PTO.....................................................................................................................................................................124 REMOVAL.............................................................................................................................................................124 INSTALLATION........................................................................................................................................................124 DISASSEMBLY.........................................................................................................................................................126 ASSEMBLY............................................................................................................................................................128 FUEL TANK...............................................................................................................................................................132 REMOVAL.............................................................................................................................................................132 INSTALLATION........................................................................................................................................................132 ENGINE .................................................................................................................................................................134 REMOVAL.............................................................................................................................................................134 INSTALLATION........................................................................................................................................................138 D85A, E-21 Serial No. 36534 and up, D85P-21 Serial No. 3689 and up......................................................................................................144 STARTING MOTOR..........................................................................................................................................................144 REMOVAL.............................................................................................................................................................144 INSTALLATION........................................................................................................................................................144 ALTERNATOR..............................................................................................................................................................145 REMOVAL.............................................................................................................................................................145 INSTALLATION........................................................................................................................................................145 AIR CONDITIONER COMPRESSOR..............................................................................................................................................146 REMOVAL.............................................................................................................................................................146 INSTALLATION........................................................................................................................................................146 ENGINE OIL COOLER.......................................................................................................................................................148 REMOVAL.............................................................................................................................................................148 INSTALLATION........................................................................................................................................................148 WATER PUMP..............................................................................................................................................................149 REMOVAL.............................................................................................................................................................149 INSTALLATION........................................................................................................................................................149 FUEL INJECTION PUMP.....................................................................................................................................................150 REMOVAL.............................................................................................................................................................150 INSTALLATION........................................................................................................................................................151 NOZZLE HOLDER...........................................................................................................................................................152 REMOVAL.............................................................................................................................................................152 INSTALLATION........................................................................................................................................................152 TURBOCHARGER............................................................................................................................................................153 REMOVAL.............................................................................................................................................................153 INSTALLATION........................................................................................................................................................153 THERMOSTAT..............................................................................................................................................................154 REMOVAL.............................................................................................................................................................154 INSTALLATtON........................................................................................................................................................154 ENGINE FRONT SEAL.......................................................................................................................................................155 REMOVAL.............................................................................................................................................................155 INSTALLATION........................................................................................................................................................155 ENGINE REAR SEAL........................................................................................................................................................156 REMOVAL.............................................................................................................................................................156 INSTALLATION........................................................................................................................................................157 CYLINDER HEAD...........................................................................................................................................................160 REMOVAL.............................................................................................................................................................160 INSTALLATION........................................................................................................................................................163 RADIATOR, POWER TRAIN OIL COOLER........................................................................................................................................166 REMOVAL.............................................................................................................................................................166 INSTALLATION........................................................................................................................................................166 ENGINE..................................................................................................................................................................167 REMOVAL.............................................................................................................................................................167 INSTALLATION........................................................................................................................................................171 RADIATOR GUARD..........................................................................................................................................................172 REMOVAL.............................................................................................................................................................172 INSTALLATION........................................................................................................................................................173 RADIATOR................................................................................................................................................................174 REMOVAL.............................................................................................................................................................174 INSTALLATION........................................................................................................................................................174 PTO.....................................................................................................................................................................175 REMOVAL.............................................................................................................................................................175 INSTALLATION........................................................................................................................................................175 DISASSEMBLY.........................................................................................................................................................176 ASSEMBLY............................................................................................................................................................178 FUEL TANK...............................................................................................................................................................181 REMOVAL.............................................................................................................................................................181 INSTALLATION........................................................................................................................................................181 20 POWER TRAIN..................................................................................................................................................................183 21 STRUCTURE AND FUNCTION...................................................................................................................................................183 GENERAL ................................................................................................................................................................184 POWER TRAIN ............................................................................................................................................................185 POWER TRAIN HYDRAULIC PIPING .........................................................................................................................................187 POWER TRAIN HYDRAULIC SYSTEM............................................................................................................................................189 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM...................................................................................................................................190 TORQUE CONVERTER........................................................................................................................................................194 TORQFLOW TRANSMISSION...................................................................................................................................................198 TRANSMISSION CONTROL....................................................................................................................................................204 TRANSMISSION CONTROL VALVE..............................................................................................................................................206 TRANSMISSION LUBRICATION VALVE..........................................................................................................................................213 TRANSMlSSlON PUMP ......................................................................................................................................................216 TRANSMISSION AND STEERING OIL STRAINER..................................................................................................................................219 TRANSMISSION AND STEERING OIL FILTER....................................................................................................................................220 BEVEL GEAR SHAFT AND STEERING CLUTCH....................................................................................................................................222 STEERING CONTROL........................................................................................................................................................224 STEERING PUMP...........................................................................................................................................................226 STEERING MAIN RELIEF VALVE..............................................................................................................................................227 STEERING AND BRAKE CONTROL VALVE........................................................................................................................................228 STEERING BRAKE..........................................................................................................................................................232 FINAL DRIVE.............................................................................................................................................................238 PTO.....................................................................................................................................................................240 22 TESTING AND ADJUSTING....................................................................................................................................................243 STANDARDS FOR TESTING AND ADJUSTING.....................................................................................................................................244 TESTING AND ADJUSTING TOOL LIST.........................................................................................................................................248 MEASURING TORQUE CONVERTER STALL SPEED..................................................................................................................................249 MEASURING OIL PRESSURE..................................................................................................................................................252 ADJUSTING FUEL CONTROL LINKAGE..........................................................................................................................................254 ADJUSTING GEAR SHIFT LEVER LINKAGE......................................................................................................................................256 ADJUSTING STEERING CLUTCH LINKAGE.......................................................................................................................................258 ADJUSTING TRAVEL OF BRAKE PEDAL.........................................................................................................................................259 ADJUSTING BRAKE PEDAL LINKAGE...........................................................................................................................................260 TROUBLESHOOTING.........................................................................................................................................................261 PREPARATION FOR TROUBLESHOOTING.....................................................................................................................................261 METHOD OF READING TROUBLESHOOTING TABLE.............................................................................................................................263 PREVENTING RECURRENCE OF THE SAME TROUBLE...........................................................................................................................265 TROUBLESHOOTING TABLE...............................................................................................................................................266 1. Torque converter temperature too high........................................................................................................................266 2. Machine does not move........................................................................................................................................268 3. Machine lacks power or speed.................................................................................................................................270 4. Machine moves when engine is started.........................................................................................................................271 5. Excessive time lag when starting machine or shifting gear....................................................................................................271 6. Excessive shock when starting machine or shifting gear.......................................................................................................272 7. Machine travels in one direction only (FORWARD or REVERSE)...................................................................................................272 8. Steering clutch does not disengage...........................................................................................................................273 9. Steering clutch slips........................................................................................................................................274 10. Steering brake does not work................................................................................................................................275 23 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................277 METHOD OF USING MANUAL..................................................................................................................................................278 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................279 TORQUE CONVERTER .......................................................................................................................................................282 REMOVAL ............................................................................................................................................................282 INSTALLATION........................................................................................................................................................282 DISASSEMBLY ........................................................................................................................................................284 ASSEMBLY............................................................................................................................................................290 TORQUE CONVERTER RELIEF VALVE ..........................................................................................................................................296 REMOVAL.............................................................................................................................................................296 INSTALLATION........................................................................................................................................................296 DISASSEMBLY.........................................................................................................................................................296 ASSEMBLY ...........................................................................................................................................................296 TORQUE CONVERTER REGULATOR VALVE........................................................................................................................................296 REMOVAL.............................................................................................................................................................296 INSTALLATION........................................................................................................................................................296 DISASSEMBLY.........................................................................................................................................................296 ASSEMBLY ...........................................................................................................................................................296 TRANSMISSION............................................................................................................................................................298 REMOVAL.............................................................................................................................................................298 INSTALLATION .......................................................................................................................................................300 DISASSEMBLY.........................................................................................................................................................302 ASSEMBLY ...........................................................................................................................................................314 TRANSMISSION CONTROL VALVE..............................................................................................................................................328 REMOVAL ............................................................................................................................................................328 INSTALLATION .......................................................................................................................................................328 DISASSEMBLY ........................................................................................................................................................330 ASSEMBLY ...........................................................................................................................................................332 TRANSMISSION LUBRICATION VALVE .........................................................................................................................................334 REMOVAL ............................................................................................................................................................334 INSTALLATION .......................................................................................................................................................334 DISASSEMBLY.........................................................................................................................................................334 ASSEMBLY............................................................................................................................................................334 BEVEL GEAR AND SHAFT....................................................................................................................................................336 REMOVAL.............................................................................................................................................................336 INSTALLATION .......................................................................................................................................................340 STEERING CLUTCH.........................................................................................................................................................346 REMOVAL.............................................................................................................................................................346 INSTALLATION........................................................................................................................................................350 DISASSEMBLY.........................................................................................................................................................354 ASSEMBLY............................................................................................................................................................356 BRAKE BOOSTER...........................................................................................................................................................358 DISASSEMBLY.........................................................................................................................................................358 ASSEMBLY............................................................................................................................................................358 STEERING RELIEF VALVE ..................................................................................................................................................360 REMOVAL.............................................................................................................................................................360 INSTALLATION........................................................................................................................................................360 DISASSEMBLY.........................................................................................................................................................360 ASSEMBLY............................................................................................................................................................360 STEERING BRAKE VALVE ...................................................................................................................................................362 REMOVAL.............................................................................................................................................................362 INSTALLATION........................................................................................................................................................362 DISASSEMBLY ........................................................................................................................................................364 ASSEMBLY............................................................................................................................................................364 TRANSMISSION PUMP.......................................................................................................................................................366 REMOVAL.............................................................................................................................................................366 INSTALLATION........................................................................................................................................................366 STEERING PUMP...........................................................................................................................................................366 REMOVAL.............................................................................................................................................................366 INSTALLATION........................................................................................................................................................366 FINAL DRIVE.............................................................................................................................................................368 DISASSEMBLY.........................................................................................................................................................368 ASSEMBLY............................................................................................................................................................372 24 MAINTENANCE STANDARD.....................................................................................................................................................379 TORQUE CONVERTER .......................................................................................................................................................380 TORQFLOW TRANSMISSON ...................................................................................................................................................382 TRANSMISSION CONTROL VALVE .............................................................................................................................................384 TRANSMISSION LUBRICATION VALVE .......................................................................................................................................388 TRANSMISSION PUMP.......................................................................................................................................................391 BEVEL GEAR SHAFT .......................................................................................................................................................394 STEERING CLUTCH.........................................................................................................................................................396 STEERING PUMP ..........................................................................................................................................................398 STEERING MAIN RELI EF VALVE.............................................................................................................................................399 STEERING AND BRAKE CONTROL VALVE........................................................................................................................................400 STEERING BRAKE..........................................................................................................................................................402 FINAL DRIVE.............................................................................................................................................................404 30 UNDERCARRIAGE................................................................................................................................................................409 31 STRUCTURE AND FUNCTION...................................................................................................................................................409 TRACK...................................................................................................................................................................410 TRACK GROUP.............................................................................................................................................................412 IDLER...................................................................................................................................................................413 IDLER CUSHION...........................................................................................................................................................414 TRACK ROLLER AND CARRIER ROLLER.........................................................................................................................................415 SUSPENSION..............................................................................................................................................................416 33 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................417 METHOD OF USING MANUAL..................................................................................................................................................418 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................419 TRACK FRAME ............................................................................................................................................................422 REMOVAL.............................................................................................................................................................422 INSTALLATION........................................................................................................................................................422 RECOIL SPRING ..........................................................................................................................................................424 REMOVAL.............................................................................................................................................................424 INSTALLATION........................................................................................................................................................427 DISASSEMBLY.........................................................................................................................................................430 ASSEMBLY............................................................................................................................................................430 IDLER...................................................................................................................................................................432 REMOVAL.............................................................................................................................................................432 INSTALLATION........................................................................................................................................................432 TRACK ROLLER............................................................................................................................................................432 REMOVAL.............................................................................................................................................................432 INSTALLATION........................................................................................................................................................432 CARRIER ROLLER .........................................................................................................................................................434 REMOVAL.............................................................................................................................................................434 INSTALLATION .......................................................................................................................................................434 TRACK SHOE .............................................................................................................................................................435 REMOVAL.............................................................................................................................................................435 INSTALLATION........................................................................................................................................................437 TRUCK LINK..............................................................................................................................................................438 DISASSEMBLY AND ASSEMBLY............................................................................................................................................438 OVERALL DISASSEMBLY.................................................................................................................................................440 OVERALL ASSEMBLY....................................................................................................................................................445 PRESS FITTING JIG DIMENSION TABLE FOR LINK PRESS....................................................................................................................459 FIELD DISASSEMBLY OF ONE LINK.......................................................................................................................................460 FIELD ASSEMBLY OF ONE LINK..........................................................................................................................................461 DISASSEMBLY OF MASTER LINK..........................................................................................................................................464 ASSEMBLY OF MASTER LINK.............................................................................................................................................466 34 MAINTENANCE STANDARD.....................................................................................................................................................469 TRACK...................................................................................................................................................................470 TRACK FRAME.............................................................................................................................................................474 RECOIL SPRING...........................................................................................................................................................475 IDLER...................................................................................................................................................................476 TRACK ROLLER............................................................................................................................................................478 CARRIER ROLLER..........................................................................................................................................................480 SUSPENSION..............................................................................................................................................................481 60 HYDRAULIC SYSTEM.............................................................................................................................................................483 61 STRUCTURE AND FUNCTION...................................................................................................................................................483 HYDRAULIC PIPING........................................................................................................................................................484 HYDRAULIC CONTROL.......................................................................................................................................................486 HYDRAULIC SYSTEM........................................................................................................................................................488 HYDRAULIC CIRCUIT DIAGRAM...............................................................................................................................................489 HYDRAULIC TANK..........................................................................................................................................................492 HYDRAULIC PUMP..........................................................................................................................................................493 BLADE CONTROL VALVE.....................................................................................................................................................494 HYDRAULIC LEVER OPERATION...............................................................................................................................................506 HYDRAULIC CYLINDER......................................................................................................................................................510 CYLINDERS STAY (D85A. E-21).............................................................................................................................................514 CYLINDER YOKE (D85P-21).................................................................................................................................................514 62 TESTING AND ADJUSTING....................................................................................................................................................515 STANDARDS FOR TESTING AND ADJUSTING.....................................................................................................................................516 TESTING AND ADJUSTING TOOL LIST.........................................................................................................................................520 MEASURING OIL PRESSURE..................................................................................................................................................521 ADJUSTING BLADE CONTROL LINKAGE.........................................................................................................................................522 ADJUSTING RIPPER CONTROL LINKAGE........................................................................................................................................523 TROUBLESHOOTING.........................................................................................................................................................525 DIAGNOSTIC TABLES...................................................................................................................................................526 1. Blade lift lacks power and speed.............................................................................................................................526 2. Blade does not lift..........................................................................................................................................527 3. The front of machine cannot be raised off ground by the blade................................................................................................528 4. Hydraulic drift of lift cylinder is large....................................................................................................................529 5. Blade moves unsteadily when leveling the ground (Control lever in “HOLD”)....................................................................................530 6. Blade lowers under the following conditions..................................................................................................................530 7. Travel of the piston rods in the right and left lift cylinders is different. (Applicable to straight-tilt dozer only)........................................530 8. Blade tilting force is lack, blade tilting speed is slow, the machine cannot be raised off ground by blade tilting force.....................................531 9. Tilt cylinder does not move off. (Tilting is impossible).....................................................................................................532 10. Hydraulic drift of tilt cylinder is large...................................................................................................................533 11. Operating force is heavy....................................................................................................................................534 12. Hydraulic drift of ripper cylinder is large.................................................................................................................535 63 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................537 METHOD OF USING MANUAL..................................................................................................................................................538 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................539 HYDRAULIC PUMP..........................................................................................................................................................542 REMOVAL ............................................................................................................................................................542 INSTALLATION........................................................................................................................................................542 BLADE CONTROL VALVE.....................................................................................................................................................542 REMOVAL ............................................................................................................................................................542 INSTALLATION........................................................................................................................................................542 DISASSEMBLY.........................................................................................................................................................544 ASSEMBLY............................................................................................................................................................546 RIPPER CONTROL VALVE ...................................................................................................................................................548 REMOVAL.............................................................................................................................................................548 INSTALLATION .......................................................................................................................................................548 DISASSEMBLY.........................................................................................................................................................550 ASSEMBLY............................................................................................................................................................550 BLADE LIFT CYLINDER ....................................................................................................................................................552 REMOVAL.............................................................................................................................................................552 INSTALLATION .......................................................................................................................................................552 BLADE TILT CYLINDER ....................................................................................................................................................552 REMOVAL.............................................................................................................................................................552 INSTALLATION........................................................................................................................................................552 RIPPER CYLINDER.........................................................................................................................................................554 REMOVAL.............................................................................................................................................................554 INSTALLATION .......................................................................................................................................................554 HYDRAULIC CYLINDER......................................................................................................................................................556 DISASSEMBLY.........................................................................................................................................................556 ASSEMBLY ...........................................................................................................................................................560 BLADE RELIEF VALVE......................................................................................................................................................564 REMOVAL.............................................................................................................................................................564 INSTALLATION........................................................................................................................................................564 RIPPER RELIEF VALVE ....................................................................................................................................................564 REMOVAL.............................................................................................................................................................564 INSTALLATION........................................................................................................................................................564 64 MAINTENANCE STANDARD.....................................................................................................................................................567 HYDRAULIC CONTROL VALVE.................................................................................................................................................569 HYDRAULIC CYLINDER......................................................................................................................................................574 CYLINDER STAY (D85A, E-21)..............................................................................................................................................576 CYLINDER YOKE (D85P-21).................................................................................................................................................576 HYDRAULIC PUMP..........................................................................................................................................................577 70 WORK EQUIPMENT...............................................................................................................................................................583 73 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................583 METHOD OF USING MANUAL..................................................................................................................................................584 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................585 BLADE...................................................................................................................................................................588 REMOVAL.............................................................................................................................................................588 INSTALLATION........................................................................................................................................................588 DISASSEMBLY ........................................................................................................................................................590 ASSEMBLY............................................................................................................................................................590 RIPPER .................................................................................................................................................................592 DISASSEMBLY.........................................................................................................................................................592 ASSEMBLY............................................................................................................................................................592 74 MAINTENANCE STANDARD.....................................................................................................................................................595 STRAIGHT TILTDOZER......................................................................................................................................................596 FIXED MULTI-SHANK RIPPER................................................................................................................................................599 80 ELECTRICAL SYSTEM............................................................................................................................................................601 81 STRUCTURE AND FUNCTION...................................................................................................................................................601 ELECTRICAL WIRING DIAGRAM...............................................................................................................................................603 EVMS ...................................................................................................................................................................609 82 TESTING AND ADJUSTING....................................................................................................................................................615 TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE............................................................................................................................616 TROUBLESHOOTING.........................................................................................................................................................619 POSITION OF CONNECTORS FOR TROUBLESHOOTING..........................................................................................................................621 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS..........................................................................................................................628 PROCEDURE FOR TROUBLESHOOTING.......................................................................................................................................632 CHECKS BEFORE TROUBLESHOOTING.......................................................................................................................................633 METHOD OF USING TROUBLESHOOTING CHART...............................................................................................................................634 TABLE OF FAILURE MODES AND CAUSES...................................................................................................................................636 M-1 NO MONITOR PANEL DISPLAY IS GIVEN WHEN STARTING SWITCH IS TURNED ON. ......................................................................................637 M-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MONITOR PANEL STAY LIGHTED AND DO NOT GO OUT. .............................................................637 M-3 WHEN STARTING SWITCH IS ON (Engine stopped), CHECK ITEMS FLASH. (CHECK item levels are at specified level.) ...............................................638 M-4 NO PREHEATING IS BEING CARRIED OUT, BUT PREHEATING DISPLAY LIGHTS UP. .....................................................................................639 M-5 WHEN STARTING SWITCH IS TURNED ON AND ENGINE IS STARTED, CHECK ITEMS FLASH. ...............................................................................640 M-6 WHEN STARTING SWITCH IS TURNED ON (Enginestopped), CAUTION ITEMS FLASH. ...................................................................................641 M-7 WHEN STARTING SWITCH IS TURNED ON (Engine started), CAUTION ITEMS FLASH.....................................................................................642 M-8 a) WHEN STARTING SWITCH IS TURNED ON (Enginestopped), BUZZER DOES NOT SOUND FOR ONE SECOND. CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND. ..........645 b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY, BUT BUZZER SOUNDS...........................................................................................645 M-9 a) WHEN STARTING SWITCH IS TURNED ON (Enginestopped), LAMPS DO NOT LIGHT UP FOR ZSECONDS. CAUTION ITEM IS FLASHING, BUT WARNING LAMP DOES NOT FLASH. ....646 b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY, BUT LAMPS LIGHT UP. ........................................................................................646 M-10 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP..........................................................................................................647 M-11 .SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED.......................................................................................................648 M-12 WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE...................................................................................................648 M-13 WATER TEMPERATURE GAUGE GIVES NO DISPLAY. .................................................................................................................649 M-14 TORQUE CONVERTER OIL TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE. .................................................................................649 M-15 TORQUE CONVERTER OIL TEMPERATURE GAUGE GIVES NO DISPLAY. .................................................................................................650 M-16 FUEL GAUGE ALWAYS DISPLAYS TANK FULL. .....................................................................................................................650 M-17 FUEL GAUGE GIVES NO DISPLAY. ..............................................................................................................................651 90 OTHERS.......................................................................................................................................................................653 91 STRUCTURE AND FUNCTION...................................................................................................................................................653 AIR CONDITIONER.........................................................................................................................................................654 93 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................657 METHOD OF USING MANUAL..................................................................................................................................................658 PRECAUTIONS WHEN CARRYING OUT OPERATION.................................................................................................................................659 CAB.....................................................................................................................................................................662 REMOVAL.............................................................................................................................................................662 INSTALLATION........................................................................................................................................................662 CAB, FLOOR FRAME........................................................................................................................................................664 REMOVAL.............................................................................................................................................................664 INSTALLATION........................................................................................................................................................664 ROPS CAB................................................................................................................................................................666 TURNING OVER........................................................................................................................................................666 INSTALLATION........................................................................................................................................................670
KOMATSU D85A-21, D85E-21, D85P-21 35001 AND UP, 3001 AND UP BULLDOZER SHOP MANUAL SEBM01542110 – PDF DOWNLOAD:
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