Komatsu D85A-21 D85E-21 D85P-21 Bulldozer Shop Manual PDF
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Komatsu D85A-21 D85E-21 D85P-21 Bulldozer Shop Manual SEBM034511 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
D85A-21 35001 and up
D85E-21 35001 and up
D85P-21 3001 and up
Description
Komatsu D85A-21 D85E-21 D85P-21 Bulldozer Shop Manual SEBM034511 – PDF DOWNLOAD
FILE DETAILS:
Komatsu D85A-21 D85E-21 D85P-21 Bulldozer Shop Manual SEBM034511 – PDF DOWNLOAD
Language : English
Pages : 633
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu D85A-21 D85E-21 D85P-21 Bulldozer Shop Manual SEBM034511 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
D85A-21 35001 and up
D85E-21 35001 and up
D85P-21 3001 and up
GENERAL PRECAUTIONS :
Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.
PREPARATIONS FOR WORK:
PRECAUTIONS DURING WORK :
TABLE OF CONTENTS:
Komatsu D85A-21 D85E-21 D85P-21 Bulldozer Shop Manual SEBM034511 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
D85A-21 35001 and up
D85E-21 35001 and up
D85P-21 3001 and up
COVER 1
CONTENTS 2
01 GENERAL 21
SPECIFICATION DRAWING 22
SPECIFICATIONS 25
WEIGHT TABLE 37
TABLE OF FUEL,COOLANT AND LUBRICANTS 43
10 ENGINE 45
12 TESTING AND ADJUSTING 45
STANDARDS FOR TESTING AND ADJUSTING 46
TESTING AND ADJUSTING TOOL LIST 48
ADJUSTING VALE CLEARANCE 50
MEASURING COMPRESSION PRESSURE 52
TESTING AND ADJUSTING FUEL INJECTION TIMING 54
MEASURING BLOW-BY 60
MEASURING AIR SUPPLEY PRESSURE (BOOST PRESSURE) 61
MEASURING EXHAUST COLOUR 62
MEASURING EXHAUST TEMPERATURE 63
MEASURING ENGINE OIL PRESSURE 64
MEASURING ENGINE SPEED 64
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 65
TROUBLESHOOTING OF ENGINE SYSTEM(S MOOE) 66
METHOD OF USING TROUBLESHOOTING CHARTS 67
S-1 STARING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 71
S-2 ENGINE DOES NOT START 72
(1) ENGINE DOES NOT TURN 72
(2) ENGINE TURNS BUT NO EXHAUST SMOKE COMES OUT (FUEL IS NOT BEING INJECTED) 73
(3) EXHAUST SMOKE COMES OUT, BUT ENGINE OES NOT START (FUEL IS BEING INJECTED) 74
S-3 ENGINE DOES NOT PICK UP SMOOTHLY 75
S-4 ENGINE STOPS DURING OPERATIONS 76
S-5 ENGINE DOES NOT ROTATE SMOOTHLY(HUNTING) 77
S-6 ENGINE LACKS OUTPUT(NO POWER) 78
S-7 EXHAUST SMOOKE IS BLACK(INCOMPLETE COMBUSTION) 79
S-8 OIL CONSUMPTION IS EXCESSIVE(OR EXHAUST SMOKE IS BLUE) 80
S-9 OIL BECOMES CONTAMINATED QUICKLY 81
S-10 FUEL CONSUMPTION IS EXCESSIVE 82
S-11 OIL IS IN COOLING WATER,OR WATER SPURTS BACK, OR WATER LEVER GOES DOWN 83
S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP(DROP IN OIL PRESSURE) 84
S-13 OIL LEVER RISES(WATER,FUEL IN OIL) 85
S-14 WATER TEMPERATURE BECOMES TOO HIGH(OVERHEATING) 86
S-15 ABNORMAL NOISE IS MADE 87
S-16 VIBRATION IS EXCESSIVE 88
13 DISASSEMBLY AND ASSEMBLY 89
METHOD OF USING MANUAL 91
PRECATIONS WHEN CARRYING OUT OPERATION 92
SPECIAL TOOL LIST 94
STARTING MOTOR 95
REMOVAL 95
INSTALLATION 95
ALTERNATOR 95
REMOVAL 95
INSTALLATION 95
AIR COMPRESSOR 95
REMOVAL 95
INSTALLATION 95
NOZZLE HOLDER 97
REMOVAL 97
INSTALLATION 97
FUEL INJECTION PUMP 97
REMOVAL 97
INSTALLATION 97
ENGINE OIL COOLER 99
REMOVAL 99
INSTALLATION 99
THERMOSTAT 99
REMOVAL 99
INSTALLATION 99
WATER PUMP 99
REMOVAL 99
INSTALLATION 99
TURBOCHARGER 101
REMOVAL 101
INSTALLATION 101
CYLINDER HEAD 103
REMOVAL 103
INSTALLATION 107
RADIATOR GUARD 113
REMOVAL 113
INSTALLATION 113
RADIATOR 115
REMOVAL 115
INSTALLATION 115
PTO 117
REMOVAL 117
INSTALLATION 117
DISASSEMBLY 119
ASSEMBLY 121
FUEL TANK 125
REMOVAL 125
INSTALLATION 125
ENGINE 127
REMOVAL 127
INSTALLATION 131
STARTING MOTOR 137
REMOVAL 137
INSTALLATION 137
ALTERNATOR 138
REMOVAL 138
INSTALLATION 138
AIR CONDITIONER COMPRESSION 139
REMOVAL 139
INSTALLATION 139
ENGINE OIL COOLER 140
REMOVAL 140
INSTALLATION 140
WATER PUMP 141
REMOVAL 141
INSTALLATION 141
FUEL INJECTION PUMP 142
REMOVAL 142
INSTALLATION 143
NOZZLE HOIDER 144
REMOVAL 144
INSTALLATION 144
TURBOCHARGER 145
REMOVAL 145
INSTALLATION 145
THERMOSTAT 146
REMOVAL 146
INSTALLATION 146
ENGINE FRONT SEAL 147
REMOVAL 147
INSTALLATION 147
ENGINE REAR SEAL 148
REMOVAL 148
INSTALLATION 149
CYLINDER HEAD 152
REMOVAL 152
INSTALLATION 155
RADIATOR, POWER TRAIN OIL COOLER 158
REMOVAL 158
INSTALLATION 158
ENGINE 159
REMOVAL 159
INSTALLATION 163
RADIATOR GUARD 164
REMOVAL 164
INSTALLATION 165
RADIATOR 166
REMOVAL 166
INSTALLATION 166
PTO 167
REMOVAL 167
INSTALLATION 167
DISASSEMBLY 168
ASSEMBLY 170
FUEL TANK 173
REMOVAL 173
INSTALLATION 173
20 POWER TRAIN 175
21 STRUCTURE AND FUNCTION 175
GENERAL 176
POWER TRAIN 177
POWER TRAIN HYDRAULIC PIPING 179
POWER TRAIN HYDRAULIC SYSTEM 183
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 184
TORQUE CONVERTER 185
TORQFLOW TRANSMISSION 189
TRANSMISSION CONTROL 195
TRANSMISSION CONTROL VALVE 197
TRANSMISSION LUBRICATION VALVE 204
TRANSMISSION PUMP 206
TRANSMISSION AND STEERING OIL STRAINER 208
TRANSMISSION ANF STEERING OIL FILTER 209
BEVEL GEAR SHAFT AND STEERING CLUTCH 210
STEERING CONTROL 212
STEERING HYDRAULIC PIPING 213
STEERING AND BRAKE HYDRAULIC SYSTEM 214
STEERING PUMP 215
STEERING MAIN LELIEF VALVE 216
STEERING AND BRAKE CONTROL VALVE 217
STEERING BRAKE 221
FINAL DRIVE 226
PTO(POWER TAKE OFF) 228
22 TESTING AND ADJUSTING 230
STANDARDS FOR TESTING AND ADJUSTING 231
TESTING AND ADJUSTING TOOL LIST 235
MEASURING TORQUE CONVERTER STALL SPEED 236
MEASURING OIL PRESSURE 238
ADJUSTING FUEL CONTROL LINKAGE 240
ADJUSTING GEAR SHIFT LEVER LINKAGE 242
ADJUSTING STEERING CLUTCH LINKAGE 244
ADJUSTING TRAVEL OF BRANKE PEDAL 245
ADJUSTING BRANK PEDAL LINKAGE 246
TROUBLESHOOTING 247
PREPARATION FOR TROUBLESHOOTING 247
METHOD OF READING TROUBLESHOOTING TABLE 249
PREVENTING RECURRENCE OF THE SAME TROUBLE 251
TROUBLESHOOTING 252
1 TORQUE CONVERTER TEMPERATURE TOO HIGH 252
2 MACHINE DOES NOT MOVE 253
3 MACHINE LACKS POWER OR SPEED 255
4 MACHINE MOVES WHEN ENGINE IS STARTED 256
5 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR 256
6 EXCESSIVE SHOCK WHEN STARTING MACHINE OR SHIFTING GEAR 257
7 MACHINE TRAVELS IN ONE DIRECTION ONLY(FORWARD OR REVERSE) 257
8 STEERING CLUTCH DOES NOT DISENGAGE 258
9 STEERING CLUTCH SLIPS 259
10 STEERING BRAKE DOES NOT WORK 260
23 DISASSEMBLY AND ASSEMBLY 261
METHOD OF USING MANUAL 262
PRECAUTIONS WHEN CARRYING OUT OPERATION 263
TORQUE CONVERTER 265
REMOVAL 265
INSTALLATION 265
DISASSEMBLY 267
ASSEMBLY 273
TORQUE CONVERTER RELIEF VALVE 279
REMOVAL 279
INSTALLATION 279
DISASSEMBLY 279
ASSEMBLY 279
TORQUE CONVERTER REGULATOR VALVE 279
REMOVAL 279
INSTALLATION 279
DISASSEMBLY 279
ASSEMBLY 279
TRANSMISSION 281
REMOVAL 281
INSTALLATION 283
DISASSEMBLY 285
ASSEMBLY 297
TRANSMISSION CONTROL VALVE 311
REMOVAL 311
INSTALLATION 311
DISASSEMBLY 313
ASSEMBLY 315
TRANSMISSION LUBRICATION VALVE 317
REMOVAL 317
INSTALLATION 317
DISASSEMBLY 317
ASSEMBLY 317
BEVEL GEAR AND SHAFT 319
REMOVAL 319
INSTALLATION 323
STEERING CLUTCH 329
REMOVAL 329
INSTALLATION 333
DISASSEMBLY 337
ASSEMBLY 339
BRAKE BOOSTER 341
DISASSEMBLY 341
ASSEMBLY 341
STEERING RELIEF VALVE 343
REMOVAL 343
INSTALLATION 343
DISASSEMBLY 343
ASSEMBLY 343
STEERING BRAKE VALVE 345
REMOVAL 345
INSTALLATION 345
DISASSEMBLY 347
ASSEMBLY 347
TRANSMISSION PUMP 349
REMOVAL 349
INSTALLATION 349
STEERING PUMP 349
REMOVAL 349
INSTALLATION 349
FINAL DRIVE 351
DISASSEMBLY 351
ASSEMBLY 355
24 MAINTENANCE STANDARD 361
TORQUE CONVERTER 362
TORQFLOW TRANSMISSION 364
TRANSMISSION CONTROL VALVE 366
TRANSMISSION LUBRICATION VALVE 370
TRANSMISSION PNMP 372
BEVEL GEAR SHAFT 374
STEERING CLUTCH 376
STEERING PUMP 378
STEERING MAIN RELIEF VALVE 379
STEERING AND BRAKE CONTROL VALVE 380
STEERING BRAKE 382
FINAL DRIVE 384
30 UNDERCARRIAGE 388
31 STRUCTURE AND FUNCTION 388
TRACK 389
TRACK GROUP 391
IDLER 392
IDLER CUSHION 393
TRACK ROLLER AND CARRIER ROLLER 394
SUSPENSION 395
33 DISASSEMBLY AND ASSEMBLY 396
METHOD OF USING MANUAL 397
PRECAUTIONS WHEN CARRYING OUT OPERATION 398
TRACK FRAME 400
REMOVAL 400
INSTALLATION 400
RECOIL SPRING 402
REMOVAL 402
INSTALLATION 405
DISASSEMBLY 408
ASSEMBLY 408
IDLER 410
REMOVAL 410
INSTALLATION 410
TRACK ROLLER 410
REMOVAL 410
INSTALLATION 410
CARRIER ROLLER 412
REMOVAL 412
INSTALLATION 412
TRACK SHOE 413
CHECKING BEFORE REMOVAL 413
REMOVAL 413
INSTALLATION 415
TRUCK LINK DISASSEMBLY AND ASSEMBLY 416
OVERALL DISSEMBLY OF TRACK SHOE 418
OVERALL ASSEMBLY OF TRACK SHOE 423
PRESS FITTING JIG DIMENSION TABLE FOR LINK PRESS 437
FIELD DISASSEMBLY OF ONE LINK 438
FIELD ASSEMBLY OF ONE LINK 439
DIASSEMBLY OF MASTER LINK 442
ASSEMBLY OF MASTER LINK 444
34 MAINTENANCE STANDARD 447
TRACK 448
TRACK FRAME 452
RECOIL SPRING 453
IDLER 454
TRACK ROLLER 456
CARRIER ROLLER 458
SUSPENSION 459
60 HYDRAULIC SYSTEM 460
61 STRUCTURE FUNCTION 460
HYDRAULIC PIPING 461
HYDRAULIC CONTROL 463
HYDRAULIC SYSTEM 465
HYDRAULIC CIRCUIT DIAGRAM 466
HYDRAULIC TANK 468
HYDRAULIC PNMP 469
HYDRAULIC CONTROL VALUE 470
HYDRAULIC LEVER OPERATION 482
HYDRAULIC CYLINDER 486
CYLINDER STAY 490
CYLINDER YOKE 490
62 TESTING AND ADJUSTING 491
STANDARDS FOR TESTING AND ADJUSTING 492
TESTING AND ADJUSTING TOOL LIST 496
MEASURING OIL PRESSURE 497
ADJUSTING BLADE CONTROL LINKAGE 498
ADJUSTING RIPPER CONTROL LINKAGE 499
TROUBLESHOOTING 500
DIAGNOSTIC TABLES 501
1 BLADE LIFT LACKS POWER AND SPEED 501
2 BLADE DOES NOT LIFT 502
3 THE FRONT OF MACHINE CANNOT BE RAISED OFF GROUND BY THE BLADE 503
4 HYDRAULIC DRIFT OF LIFT CYLINDER IS LARGE 504
5 BLADE MOVES UNSTEADILY WHEN LEVELING THE GROUND(CONTROL LEVER IN “HOLD”) 505
6 BLADE LOWERS UNDER THE FOLLOWING CONDITIONS 505
7 TRAVEL OF THE PISTON RODS IN THE RIGHT AND LEFT LIFT CYLINDERS IS DIFFERENT 505
8 BLADE TITING FORCE IS LACK, BLADE TITING SPEED IS SLOW, THE MACHINE CANNOT BE RAISED OFF GROUND BY BLADE TILTING FORCE 506
9 TILT CYLINDER DOES NOT MOVE OFF (TILTING IS IMPOSSIBLE) 507
10 HYDRAULIC DRIFT OF TILT CYLINDER IS LARGE 508
11 OPERATING FORCE IS HEAVY 509
12 HYDRAULIC DRIFT OF RIPPER CYLINDER IS LARGE 510
63 DISASSEMBLY AND ASSEMBLY 511
METHOD OF USING MANUAL 512
PRECAUTIONS WHEN CARRYING OUT OPERATION 513
HYDRAULIC PUMP 516
REMOVAL 516
INSTALLATION 516
BLADE CONTROL VALVE 516
REMOVAL 516
INSTALLATION 516
DISASSEMBLY 518
ASSEMBLY 520
RIPPER CONTROL VALVE 522
REMOVAL 522
INSTALLATION 522
DISASSEMBLY 524
ASSEMBLY 524
BLADE LIFT CYLINDEF 526
REMOVAL 526
INSTALLATION 526
BLADE TILT CYLINDER 526
REMOVAL 526
INSTALLATION 526
RIPPER CYLINDER 528
REMOVAL 528
INSTALLATION 528
HYDRAULIC CYLINDER 530
DISASSEMBLY 530
ASSEMBLY 534
BLADE RELIEF VALVE 538
REMOVAL 538
INSTALLATION 538
RIPPER RELIEF VALVE 538
REMOVAL 538
INSTALLATION 538
64 MAINTENANCE STANDARD 540
HYDRAULIC CONTROL VALVE 541
HYDRULIC CYLINDER 546
CYLINDER STAY 548
CYLINDER YOKE 548
HYDRAULIC PUMP 549
70 WORK EQUIPMENT 550
71 STRUCTURE AND FUNCTION 550
STRAIGHT TILTDOZER 551
FIXED MULTI-SHANK RIPPER 553
73 DISASSEMBLY AND ASSEMBLY 554
METHOD OF USING MANUAL 555
PRECAUTION WHEN CARRYING OUT OPERATION 556
BLADE 558
REMOVAL 558
INSTALLATION 558
DISASSEMBLY 560
ASSEMBLY 560
RIPPER 562
DISASSEMBLY 562
ASSEMBLY 562
74 MAINTENANCE STANDARD 564
STRAIGHT TILTDOZER 565
FIXED MULIT-SHANK RIPPER 568
80 ELECTRICAL SYSTEM 569
81 STRUCTURE AND FUNCTION 569
ELECTRICAL WIRING DIAGRAM 570
EVMS 575
82 TESTING AND ADJUSTING 581
TABLE OF ELECTRICAL JUDGEMENT STANDARD VALUE 582
TROUBLESHOOTING 584
POSITION OF CONNECTORS FOR TROUBLESHOOTING 585
CONNECTION TABLE FOR CONNECTION PIN NUMBERS 591
PROCEDURE FOR TROUBLESHOOTING 595
CHECKS BEFORE TROUBLESHOOTING 596
METHOD OF USING TROUBLESHOOTING CHART 597
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM) 599
M-1 NO MONITOR PANEL DISPLAY IS GIVEN WHEN STARTING SWITCH IS TURNED ON 600
M-2 WHEN STARTING SWITCH IS TURNED ON, ALL LAMPS ON MONITOR PANEL STAY LIGHTED AND DO NOT GO OUT 600
M-3 WHEN STARTING SMITCH IS ON(ENGINE STOPPED),CHECK ITEMS FLASH (CHECK ITTEM LEVELS ARE AT SPECIFIED LEVEL) 601
M-4 NO PREHEATING IS BEING CARRIED OUT,BUT PREHEATING DISPLAY LIGHTS UP 602
M-5 WHEN STARTING SMITCH IS TURNED ON AND ENGINE IS STARTED ,CHECK ITEMS FLASH 603
M-6 WHEN STARTING SWITCH IS TURNED ON (ENGINE STOPPED) CAUTION ITEMS FLASH 604
M-7 WHEN STARTING SWITCH IS TURNED ON (ENGINE STARTED)CAUTION ITEMS FLASH(WHEN THERE IS NO ABNORMALITY IN THE ENGINE OR IN THE CHECK ITEMS) 605
M-8 a) WHEN STARTING SWITCH IS TURNED ON(ENGINE STOPPED)BUZZER DOES DOT SOUND FOR ONE SECOND CAUTION ITEM IS FLASHING BUT BUZZER DOES NOT SOUND 608
M-8 b) THERE IS NO ABNORMALITY IN MONITOR DISPLAY, BUT BUZZER SOUNDS 608
M-9 a) WHEN STARTING SWITCHG IS TURNED ON (ENGINE STOPPED),LAMPS DO NOT LIGHT UP FOR 2 SECONDS CAUTION ITEM IS FLASHING ITEM IS FLASHING ,BUT WARNING LAMP DOES NOT FLASH 609
M-9 b) THERE IS NO ABNORMALITY IN MONITOR DISPLY ,BUT LAMPS LIGHT UP 609
M-10 PANEL LIGHTING OF MONITOR PANEL DOES NOT LIGHT UP 610
M-11 SEVER METER DOES NOT MOVE AFTER ENGINE IS STARTED 611
M-12 WATER TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE 611
M-13 WATER TEMPERATURE GAUGE GIVES NO DISPLAY 612
M-14 TORQUE CONVERTER OIL TEMPERATURE GAUGE SHOWS ABNORMALLY LOW TEMPERATURE 612
M-15 TORQUE CONVERTER OIL TEMPERATURE GAUGE GIVES NO DISPLAY 613
M-16 FUEL GAUGE ALWAYS DISPLAYS TANK FULL 613
M-17 FUEL GAUGE GIVES NO DISPLAY 614
90 OTHERS 615
91 STRUCTURE AND FUNCTION 615
AIR CONDITIONER 616
93 DISASSEMBLY AND ASSEMBLY 618
METHOD OF USING MANUAL 619
PRECAUTIONS WHEN CARRYING OUT OPERATION 620
CAB 622
REMOVAL 622
INSTALLATION 622
CAB,FLOOR FRAME 624
REMOVAL 624
INSTALLATION 624
CAB 626
TURNING OVER 626
INSTALLATION 630
IMAGES PREVIEW OF THE MANUAL:
S.V 27/12/24
