Komatsu D85A-21,D85E-21,D85P-21 Crawler Bulldozer Shop Manual SEBM01542110 PDF
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Komatsu D85A-21,D85E-21,D85P-21 Crawler Bulldozer Shop Manual SEBM01542110 – 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 Crawler Bulldozer Shop Manual SEBM01542110 – PDF DOWNLOAD
FILE DETAILS:
Komatsu D85A-21,D85E-21,D85P-21 Crawler Bulldozer Shop Manual SEBM01542110 – PDF DOWNLOAD
Language : English
Pages : 676
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu D85A-21,D85E-21,D85P-21 Crawler Bulldozer Shop Manual SEBM01542110 – PDF DOWNLOAD
- MACHINE MODEL SERIAL NUMBER
D85A-21 35001 and up
D85E-21 35001 and up
D85P-21 3001 and up
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
DESCRIPTION:
Komatsu D85A-21,D85E-21,D85P-21 Crawler Bulldozer Shop Manual SEBM01542110 – PDF DOWNLOAD
- MACHINE MODEL SERIAL NUMBER
D85A-21 35001 and up
D85E-21 35001 and up
D85P-21 3001 and up
G.B 27/12/24
