Komatsu D85C-21 Pipe Layer Shop Manual SEN04766-00 – PDF DOWNLOAD

Description

Komatsu D85C-21 Pipe Layer Shop Manual SEN04766-00 – PDF DOWNLOAD

IMAGES PREVIEW OF THE MANUAL:

Need help? Contact: [email protected]

TABLE OF CONTENTS:

Komatsu D85C-21 Pipe Layer Shop Manual SEN04766-00 – PDF DOWNLOAD

COVER 1
CONTENTS 2
01 GENERAL 0
GENERAL ASSEMBLY DRAWING 22
SPECIFICATIONS 24
WEIGHT TABLE 30
TABLE OF OIL AND COOLANT QUANTITIES 33
10 STRUCTURE AND FUNCTION 0
RADIATOR SHUTTER 38
POWER TRAIN 40
POWER TRAIN HYDRAULIC PIPING DIAGRAM 42
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM 44
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 45
PTO 46
TORQUE CONVERTER 48
TRANSMISSION CONTROL 52
TORQFLOW TRANSMISSION 54
TRANSMISSION CONTROL VALVE 60
TRANSMISSION LUBRICATION VALVE 65
STEERING, BRAKE CONTROL 66
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 67
STEERING MAIN LELIEF VALVE 69
STEERING AND BRAKE CONTROL VALVE 70
STEERING BRAKE 74
TRANSMISSION AND STEERING OIL STRAINER 78
TRANSMISSION AND STEERING OIL FILTER 79
FINAL DRIVE 80
TRACK GROUP 82
SUSPENSION 83
GATE FRAME 84
WINCH CONTROL 86
HYDRAULIC CIRCUIT DIAGRAM FOR WINCH 89
WINCH 90
POWER TRAIN OF WINCH 98
HIGH-LOW VALVE 104
PPC VALVE 105
FLOW DIVIDER VALVE 107
WINCH OIL FILTER 110
WINCH OIL STRAINER 110
COUNTERWEIGHT HYDRAULIC TANK 111
COUNTERWEIGHT PIPING 112
COUNTERWEIGHT CONTROL 113
HYDRAULIC CIRCUIT SCHEMATICS FOR COUNTERWEIGHT 114
HYDRAULIC CIRCUIT DIAGRAM FOR COUNTERWEIGHT 115
COUNTERWEIGHT 116
COUNTERWEIGHT CONTROL VALVE 118
BOOM 119
SAFETY DEVICE 120
CAB 125
HEATER 127
ACTUAL ELECTRICAL WIRING DIAGRAM 128
ELECTRICAL CIRCUIT DIAGRAM 131
20 TESTING AND ADJUSTING 0
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS 138
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS 141
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 145
ADJUSTING VALVE CLEARANCE 146
MEASURING COMPRESSION PRESSURE 147
TESTING AND ADJUSTING FUEL INJECTION TIMING 148
MEASURING ENGINE OIL PRESSURE 150
MEASURING EXHAUST COLOR 151
MEASURING EXHAUST TEMPERATURE 152
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 153
MEASURING BLOW-BY PRESSURE 154
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE) 155
MEASURING ENGINE SPEED 156
MEASURING TORQUE CONVERTER STALL SPEED 157
BLEEDING AIR 158
ADJUSTING STROKE, LINKAGE 159
1 ADJUSTING FUEL CONTROL LINKAGE 159
2 ADJUSTING GEAR SHIFT LEVER LINKAGE 161
3 ADJUSTING STEERING LEVER LINKAGE 163
4 ADJUSTING TRAVEL OF BRAKE PEDAL 164
5 ADJUSTING BRAKE PEDAL LINKAGE 165
6 ADJUSTING COUNTERWEIGHT CONTROL LINKAGE 166
7 ADJUSTING BOOM KICKOUT CONTROL LINKAGE 167
8 ADJUSTING WINCH CONTROL LINKAGE 168
MEASURING POWER TRAIN OIL PRESSURE 170
MEASURING COUNTERWEIGHT OIL PRESSURE 172
MEASURING WINCH OIL PRESSURE 173
MEASURING LEAKAGE INSIDE CYLINDER 176
ADJUSTING CLEARANCE OF IDLER 177
TROUBLESHOOTING 179
POINTS TO REMEMBER WHEN TROUBLESHOOTING 180
SEQUENCE OF EVENTS IN TROUBLESHOOTING 181
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 182
CHECKS BEFORE TROUBLESHOOTING 190
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 191
METHOD OF USING TROUBLESHOOTING CHARTS 192
S-1 Starting performance is poor (starting always takes time) 196
S-2 Engine does not start 197
(1) Engine does not turn 197
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected) 198
(3) Exhaust smoke comes out, but engine does not start (Fuel is being injected) 199
S-3 Engine does not pick up smoothly 200
S-4 Engine stops during operations 201
S-5 Engine does not rotate smoothly (hunting) 202
S-6 Engine lacks output (no power) 203
S-7 Exhaust smoke is black 204
S-8 Oil consumption is excessive (or exhaust smoke is blue) 205
S-9 Oil becomes contaminated quickly 206
S-10 Fuel consumption is excessive 207
S-11 Oil is in cooling water 208
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 209
S-13 Oil level rises (water, fuel in oil) 210
S-14 Water temperature becomes too high (overheating) 211
S-15 Abnormal noise is made 212
S-16 Vibration is excessive 213
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 215
H-1 Torque converter oil temperature is too high 216
H-2 Machine does not move 218
H-3 Machine lacks power or speed 220
H-4 Machine moves when engine is started 221
H-5 Excessive time lag when starting machine or shifting gear 221
H-6 Excessive shock when starting off or shifting gear 222
H-7 Machine moves in only one direction (FORWARD or REVERSE) 223
H-8 Steering clutch is not disengaged 224
H-9 Steering clutch slips 225
H-10 Steering brake does not work 226
H-11 Lack of power, speed when retract counterweight 227
H-12 lmpossible to retract counterweight 228
H-13 Excessive hydraulic drift of counterweight cylinder 229
H-14 Defective boom RAISE, LOWER (speed, raising force, lowering force 230
H-15 Defective hook RAISE, LOWER (speed, raising force, lowering force) 231
H-16 Excessive hydraulic drift of boom 232
H-17 Excessive hydraulic drift of hook 233
H-18 Play when operating hook 234
H-19 Play when operating boom 235
H-20 Excessive time lag when operating hook 236
H-21 Excessive time lag when operating boom 237
H-22 Excessive inching amount 238
H-23 Winch free fall does not work 239
H-24 Winch overheats 240
H-25 Excessive noise when operating winch clutch, brake 241
H-26 Control lever is heavy 242
30 DISASSEMBLY AND ASSEMBLY 0
METHOD OF USING MANUAL 245
PRECAUTIONS WHEN CARRYING OUT OPERATION 247
SPECIAL TOOL LIST 249
STARTING MOTOR REMOVAL AND INSTALLATION 253
ALTERNATOR REMOVAL AND INSTALLATION 254
ENGINE OIL COOLER REMOVAL AND INSTALLATION 255
WATER PUMP REMOVAL AND INSTALLATION 256
FUEL INJECTION PUMP REMOVAL 257
FUEL INJECTION PUMP INSTALLATION 258
NOZZLE HOLDER REMOVAL AND INSTALLATION 259
TURBOCHARGER REMOVAL AND INSTALLATION 260
THERMOSTAT REMOVAL AND INSTALLATION 261
ENGINE FRONT SEAL REMOVAL AND INSTALLATION 262
ENGINE REAR SEAL REMOVAL 263
ENGINE REAR SEAL INSTALLATION 264
CYLINDER HEAD REMOVAL 267
CYLINDER HEAD INSTALLATION 270
RADIATOR, POWER TRAIN OIL COOLER REMOVAL AND INSTALLATION 273
ENGINE REMOVAL 274
ENGINE INSTALLATION 278
TORQUE CONVERTER REMOVAL 279
TORQUE CONVERTER INSTALLATION 281
TORQUE CONVERTER DISASSEMBLY 283
TORQUE CONVERTER ASSEMBLY 288
TORQFLOW TRANSMISSION REMOVAL 294
TORQFLOW TRANSMISSION INSTALLATION 296
TORQFLOW TRANSMISSION DISASSEMBLY 298
TORQFLOW TRANSMISSION ASSEMBLY 309
TRANSMISSION CONTROL VALVE REMOVAL AND INSTALLATION 323
TRANSMISSION CONTROL VALVE DISASSEMBLY 324
TRANSMISSION CONTROL VALVE ASSEMBLY 326
TRANSMISSION LUBRICATION VALVE REMOVAL AND INSTALLATION 328
TRANSMISSION PUMP REMOVAL AND INSTALLATION 329
BEVEL GEAR, SHAFT REMOVAL 330
BEVEL GEAR, SHAFT INSTALLATION 333
STEERING CLUTCH REMOVAL 337
STEERING CLUTCH INSTALLATION 340
STEERING CLUTCH DISASSEMBLY 343
STEERING CLUTCH ASSEMBLY 345
STEERING BRAKE VALVE DISASSEMBLY 348
STEERING BRAKE VALVE ASSEMBLY 350
FINAL DRIVE DISASSEMBLY 352
FINAL DRIVE ASSEMBLY 356
TRACK SHOE REMOVAL 361
TRACK SHOE INSTALLATION 363
TRACK FRAME REMOVAL 364
TRACK FRAME INSTALLATION 365
RECOIL SPRING REMOVAL 366
RECOIL SPRING INSTALLATION 369
RECOIL SPRING DISASSEMBLY 372
RECOIL SPRING ASSEMBLY 373
IDLER REMOVAL AND INSTALLATION 374
TRACK ROLLER REMOVAL AND INSTALLATION 375
CARRIER ROLLER REMOVAL AND INSTALLATION 376
RIGHT, CENTER GATE FRAME REMOVAL 377
RIGHT, CENTER GATE FRAME INSTALLATION 379
COUNTERWEIGHT FRAME REMOVAL 381
COUNTERWEIGHT FRAME INSTALLATION 383
BOOM, LEFT GATE FRAME REMOVAL AND INSTALLATION 385
WINCH DISMOUNTING 386
WINCH MOUNTING 388
WINCH CONTROL AND PPC VALVE DISMOUNTING AND MOUNTING 390
HIGH/LOW VALVE DISMOUNTING AND MOUNTING 391
WINCH DISASSEMBLY 392
・ WINCH 392
・ BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH 418
・ BOOM BRAKE, HOOK BRAKE 421
・ PPC VALVE 424
・ CONTROL 426
・ HI, LO SELECTOR VALVE 429
・ FLOW DIVIDER VALVE 431
・ STRAINER ASSEMBLY 432
・ FILTER ASSEMBLY 433
WINCH ASSEMBLY 434
・ WINCH 434
・ BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH 434
・ BOOM BRAKE, HOOK BRAKE 438
・ PPC VALVE ASSEMBLY 441
・ CONTROL 444
・ HI, LO SELECTOR VALVE 447
・ FLOW DIVIDER VALVE 449
・ STRAINER 450
・ FILTER 451
・ WINCH 452
WINCH PUMP DISMOUNTING AND MOUNTING 481
COUNTERWEIGHT PUMP REMOVAL AND INSTALLATION 482
COUNTERWEIGHT CYLINDER REMOVAL AND INSTALLATION 483
COUNTERWEIGHT CYLINDER DISASSEMBLY 484
COUNTERWEIGHT CYLINDER ASSEMBLY 486
COUNTERWEIGHT CONTROL VALVE REMOVAL AND INSTALLATION 488
COUNTERWEIGHT CONTROL VALVE DISASSEMBLY 490
COUNTERWEIGHT CONTROL VALVE ASSEMBLY 492
CAUTION WHEN ASSEMBLING SHEAVE BLOCK 494
CAB REMOVAL AND INSTALLATION 495
40 MAINTENANCE STANDARD 0
ENGINE MOUNT 498
PTO 500
TORQUE CONVERTER 502
TORQFLOW TRANSMISSION 504
TRANSMISSION CONTROL VALVE 506
TRANSMISSION LUBRICATION VALVE 508
TRANSMISSION PUMP 509
BEVEL GEAR SHAFT 510
STEERING CLUTCH 512
STEERING BRAKE 514
STEERING AND BRAKE CONTROL VALVE 516
STEERING MAIN RELIEF VALVE 518
STEERING PUMP 520
FINAL DRIVE 522
TRACK FRAME 524
RECOIL SPRING 525
TRACK 526
LDLER 528
TRACK ROLLER 530
CARRIER ROLLER 532
SUSPENSION 533
WINCH PUMP 534
COUNTERWEIGHT PUMP 535
HIGH-LOW VALVE 536
PPC VALVE 537
FLOW DIVIDER VALVE 538
WINCH 540
WINCH CLUTCH 542
WINCH BRAKE 544
COUNTERWEIGHT CONTROL VALVE 546
COUNTERWEIGHT CYLINDER 547
SLOW RETURN VALVE 548
COUNTERWEIGHT 549
BOOM, HOOK AND SHEAVE 550

DESCRIPTION:

Komatsu D85C-21 Pipe Layer Shop Manual SEN04766-00 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
D85C-21 36551 and up

FOREWORD:

This shop manual has been prepared as an aid to improve the quality of repairs by giving the operator 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.
The manual is divided into chapters on each main group of components; these chapters are further divided into the
following sections.
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 ADJUSTMENTS
This sections 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.
REMOVAL AND INSTALLATION
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.
STANDARD MAINTENANCE
This section gives the judgement standards when inspecting disassembled parts.

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
• You will be directed to the download page as soon as the purchase is completed. The whole payment and downloading process will take anywhere between 2-5 minutes
• Need any other service / repair / parts manual, please feel free to contact [email protected] . We still have 50,000 manuals unlisted

S.V