Komatsu D85E-SS-2 Bulldozer Shop Manual SEBM003002 PDF

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Komatsu D85E-SS-2 Bulldozer Shop Manual SEBM003002 – PDF DOWNLOAD

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Komatsu D85E-SS-2 Bulldozer Shop Manual SEBM003002 – PDF DOWNLOAD 

Language : English
Pages : 584
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D85E-SS-2 Bulldozer Shop Manual SEBM003002 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
D85E-SS-2                    3001 and up

COVER 1
CONTENTS 2
01 GENERAL 26
GENERAL ASSEMBLY DRAWING 27
SPECIFICATIONS 28
WEIGHT TABLE 31
TABLE OF FUEL, COOLANT AND LUBRICANTS 33
10 STRUCTURE AND FUNCTION 35
RADIATOR, OIL COOLER 36
ENGINE CONTROL 38
POWER TRAIN SYSTEM 40
POWER TRAIN SKELETON 41
POWER TRAIN UNIT 42
POWER TRAIN HYDRAULIC PIPING DIAGRAM 43
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 45
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM 46
DAMPER, UNIVERSAL JOINT 47
TORQUE CONVERTER AND PTO 49
TRANSMISSION CONTROL 51
TRANSMISSION 53
TRANSMISSION CONTROL VALVE 59
MAIN RELIEF VALVE 66
LUBRICATION RELIEF VALVE 68
STEERING, BRAKE CONTROL 69
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 70
STEERING CONTROL VALVE 76
REDUCING VALVE 83
SCAVENGING PUMP STARAINER 84
POWER TRAIN OIL STRAINER 85
POWER TRAIN OIL FILTER 86
FINAL DRIVE 87
MAIN FRAME 90
TRACK FRAME 91
RECOIL SPRING 93
SUSPENSION 95
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 99
WORK EQUIPMENT CONTROL 101
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM 102
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM 103
HYDRAULIC TANK AND FILTER 104
MAIN CONTROL VALVE 108
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT 110
PISTON VALVE 111
WORK EQUIPMENT 112
ELECTRICAL CIRCUIT DIAGRAM 113
ENGINE CONTROL 114
MACHINE MONITOR SYSTEM 115
SENSORS 118
20 TESTING AND ADJUSTING 120
STANDARD VALUE TABLE FOR ENGINE 121
STANDARD VALUE TABLE FOR CHASSIS 123
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 127
TOOL LIST FOR TESTING AND ADJUSTING 128
ADJUSTING VALVE CLEARANCE 129
MEASURING COMPRESSION PRESSURE 130
MEASURING BLOWBY 131
ADJUSTING FUEL INJECTION TIMING 132
MEASURING EXHAUST COLOR 134
MEASURING BOOST PRESSURE 135
MEASURING EXHAUST TEMPERATURE 136
MEASURING ENGINE OIL PRESSURE 137
MEASURING ENGINE SPEED 137
TESTING FAN BELT TENSION 138
MEASURING SPEED AT TORQUE CONVERTER STALL 139
ADJUSTING FUEL CONTROL LINKAGE 140
ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE 144
ADJUSTING BRAKE PEDAL LINKAGE 148
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE 149
MEASURING POWER TRAIN OIL PRESSURE 150
MEASURING AND ADJUSTING BLADE CONTROL OIL PRESSURE 157
BLEEDING AIR FROM HYDRAULIC CYLINDER 158
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 158
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE 159
PROCEDURE FOR TESTING SENSORS 160
TROUBLESHOOTING 161
POINTS TO REMEMBER WHEN TROUBLESHOOTING 162
SEQUENCE OF EVENTS IN TROUBLESHOOTING 163
POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE 164
CHECK BEFORE TROUBLESHOOTING 172
METHOD OF USING TROUBLESHOOTING CHARTS 177
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 179
CONNECTOR POSITION DRAWING 180
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 181
ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM 191
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 192
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME) 193
S-2 ENGINE DOES NOT START 194
① ENGINE DOES NOT TURN 194
② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED) 195
③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED) 196
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) 197
S-4 ENGINE STOPS DURING OPERATIONS 198
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING) 199
S-6 ENGINE LACKS OUTPUT (NO POWER) 200
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION) 201
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE) 202
S-9 OIL BECOMES CONTAMINATED QUICKLY 203
S-10 FUEL CONSUMPTION IS EXCESSIVE 204
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN 205
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE) 206
S-13 OIL LEVEL RISES 207
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING) 208
S-15 ABNORMAL NOISE IS MADE 209
S-16 VIBRATION IS EXCESSIVE 210
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE) 211
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEM) 212
H-1 BRAKES DOES NOT WORK 213
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN S STRAIGHT LINE) 214
H-3 OVERTURNS WHEN TURING 215
H-4 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING AND DIRECTIONAL LEVER IS OPERATED) 216
H-5 EXCESSIVE TIME LAG 217
H-6 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE) 217
H-7 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD) 218
H-8 MACHINE DOES NOT MOVE IN AND SPEED RANGE 220
H-9 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH 222
H-10 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW 224
H-11 ABNORMAL NOISE IS GENERATED FROM AROUND HYDRAULIC PUMP 226
H-12 BLADE LIFTING SPEED IS SLOW OR LACKS POWER 227
H-13 BLADE DOES NOT RAISE 228
H-14 HYDRAULIC DRIFT OF BLADE LIFT IS EXCESSIVE 228
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 229
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM) 230
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON 231
E-2 LAMPS DO NO LIGHT UP 233
a) FRONT LAMPS 233
b) REAR LAMPS 234
E-3 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO 235
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) 239
M-1 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE 240
M-2 ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE 241
30 DISASSEMBLY AND ASSEMBLY 242
METHOD OF USING MANUAL 244
PRECAUTIONS WHEN CARRYING OUT OPERATION 247
SPECIAL TOOL LIST 249
STARTING MOTOR 253
REMOVAL 253
INSTALLATION 253
ALTERNATOR 254
REMOVAL 254
INSTALLATION 254
ENGINE OIL COOLER CORE 256
REMOVAL 256
INSTALLATION 256
FUEL INJECTION PUMP 257
REMOVAL 257
INSTALLATION 258
WATER PUMP 259
REMOVAL 259
INSTALLATION 259
TURBOCHARGER 261
REMOVAL 261
INSTALLATION 261
NOZZLE HOLDER 262
REMOVAL 262
INSTALLATION 262
THERMOSTAT 263
REMOVAL 263
INSTALLATION 263
CYLINDER HEAD 265
REMOVAL 265
INSTALLATION 268
ENGINE FRONT SEAL 275
REMOVAL 275
INSTALLATION 276
ENGINE REAR SEAL 277
REMOVAL 277
INSTALLATION 278
FUEL TANK 281
REMOVAL 281
INSTALLATION 281
RADIATOR 284
REMOVAL 284
INSTALLATION 286
HYDRAULIC OIL COOLER 286
REMOVAL 286
INSTALLATION 286
ENGINE 287
REMOVAL 287
INSTALLATION 289
DAMPER 293
REMOVAL 293
INSTALLATION 295
POWER TRAIN UNIT 298
REMOVAL 298
INSTALLATION 303
SEPARATION 304
CONNECTION 306
TORQUE CONVERTER 307
DISASSEMBLY 307
ASSEMBLY 309
PTO 312
DISASSEMBLY 312
ASSEMBLY 315
TORQFLOW TRANSMISSION 319
DISASSEMBLY 319
ASSEMBLY 328
STEERING CASE 342
DISASSEMBLY 342
ASSEMBLY 348
TORQUE CONVERTER VALVE 359
REMOVAL 359
INSTALLATION 359
DISASSEMBLY 360
ASSEMBLY 360
TRANSMISSION CONTROL VALVE 361
REMOVAL 361
INSTALLATION 361
DISASSEMBLY 363
ASSEMBLY 363
STEERING CONTROL VALVE 368
REMOVAL 368
INSTALLATION 368
DISASSEMBLY 369
ASSEMBLY 371
REDUCING VALVE 373
REMOVAL 373
INSTALLATION 373
DISASSEMBLY 374
ASSEMBLY 374
SCAVENGING PUMP 375
REMOVAL 375
INSTALLATION 375
POWER TRAIN PUMP 376
REMOVAL 376
INSTALLATION 376
FINAL DRIVE 377
REMOVAL 377
INSTALLATION 378
DISASSEMBLY 379
ASSEMBLY 383
TRACK FRAME 388
REMOVAL 388
INSTALLATION 389
RECOIL SPRING 390
REMOVAL 390
INSTALLATION 390
DISASSEMBLY 391
ASSEMBLY 393
IDLER 399
REMOVAL 399
INSTALLATION 399
DISASSEMBLY 401
ASSEMBLY 403
TRACK ROLLER 407
REMOVAL 407
INSTALLATION 407
DISASSEMBLY 408
ASSEMBLY 409
CARRIER ROLLER 411
REMOVAL 411
INSTALLATION 412
DISASSEMBLY 413
ASSEMBLY 414
TRACK SHOE 415
CHECKING BEFORE REMOVAL 415
REMOVAL 415
INSTALLATION 417
OVERALL DISASSEMBLY 421
OVERALL ASSEMBLY 426
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 440
FIELD DISASSEMBLY OF ONE LINK 441
FIELD ASSEMBLY OF ONE LINK 442
PIVOT SHAFT 449
REMOVAL 449
INSTALLATION 449
EQUALIZER BAR 450
REMOVAL 450
INSTALLATION 451
EQUALIZER BAR SIDE BUSHING 452
REMOVAL 452
INSTALLATION 452
SEGMENT TEETH 453
REMOVAL 453
INSTALLATION 453
WORK EQUIPMENT PUMP 454
REMOVAL 454
INSTALLATION 454
MAIN CONTROL VALVE 455
REMOVAL 455
INSTALLATION 455
DISASSEMBLY 456
ASSEMBLY 458
SUCTION VALVE 460
REMOVAL 460
INSTALLATION 460
BLADE LIFT CYLINDER 462
REMOVAL 462
INSTALLATION 462
DISASSEMBLY 463
ASSEMBLY 465
BLADE 467
REMOVAL 467
INSTALLATION 468
SWEEP, CANOPY 469
REMOVAL 469
INSTALLATION 469
DASHBOARD 470
REMOVAL 470
INSTALLATION 470
FLOOR FRAME 471
REMOVAL 471
INSTALLATION 474
40 MAINTENANCE STANDARD 475
ENGINE MOUNT 476
POWER TRAIN UNIT MOUNT 477
DAMPER, UNIVERSAL JOINT 478
TORQUE CONVERTER, PTO 479
TRANSMISSION 481
TRANSMISSION CONTROL VALVE 483
MAIN RELIEF VALVE 485
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 486
STEERING CONTROL VALVE 488
POWER TRAIN, LUBRICATION PUMP 489
FINAL DRIVE 490
HULL FRAME 492
TRACK FRAME, RECOIL SPRING 493
IDLER 495
TRACK ROLLER 496
CARRIER ROLLER 497
TRACK SHOE 498
SUSPENSION 502
HYDRAULIC PUMP 506
MAIN CONTROL VALVE 508
WORK EQUIPMENT CYLINDER 510
WORK EQUIPMENT 511
CUTTING EDGE, END BIT 513
90 OTHERS 514
1 GENERAL 515
1-1 SPECIFICATION 515
1-2 POWER TRAIN SYSTEM 516
2 STRUCTURE AND FUNCTION 517
2-1 GENERAL VIEW 517
2-2 WINCH SECTION 518
2-3 HYDRAULIC SYSTEM 520
2-3-1 PIPING 520
2-3-2 HYDRAULIC CIRCUIT DIAGRAM 521
2-3-3 GENERAL VIEW OF CONTROL VALVE AND FUNCTION 522
2-3-4 CLUTCH STRUCTURE AND FUNCTION (INCL LUBRICATION VALVE) 523
2-4 CONTROL OF WINCH 525
2-5 FAIRLEAD 526
3 TESTING AND ADJUSTING 527
3-1 STANDARD VALUE TABLE FOR TOWING WINCH 527
3-2 TOOL LIST FOR TESTING AND ADJUSTING 528
3-3 ADJUSTING TOWING WINCH CONTROL LEVER 529
3-4 MEASURING AND ADJUSTING TOWING WINCH OIL PRESSURE 530
3-5 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEMS) 532
H-1 TOWING WINCH DOES NOT TURN 533
H-2 TOWING WINCH BRAKE DOES NOT WORK 534
4 DISASSEMBLY AND ASSEMBLY 535
METHOD OF USING MANUAL 535
PRECAUTIONS WHEN CARRYING OUT OPERATION 536
4-1 SPECIAL TOOL LIST 538
4-2 TOWING WINCH ASSEMBLY 539
REMOVAL 539
INSTALLATION 539
4-3 TOWING WINCH PUMP ASSEMBLY 540
REMOVAL 540
INSTALLATION 540
4-4 TOWING WINCH CONTROL VALVE ASSEMBLY 541
REMOVAL 541
INSTALLATION 541
DISASSEMBLY 542
ASSEMBLY 544
4-5 TOWING WINCH ASSEMBLY 546
DISASSEMBLY 546
ASSEMBLY 559
4-6 ASSEMBLING INFORMATION 579
4-6-1 BEARING CLEARANCE AND GEAR BACKLASH 579
5 MAINTENANCE STANDARD 580
5-1 CLUTCH 580
5-2 BRAKE 581
5-3 VALVE 582
5-4 TOWING WINCH PUMP 584

DESCRIPTION:

Komatsu D85E-SS-2 Bulldozer Shop Manual SEBM003002 – PDF DOWNLOAD 

MACHINE MODEL    SERIAL NUMBER
D85E-SS-2                    3001 and up

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 judge- ments. 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 fur- ther 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 under- standing of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and mainte nance standards.
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” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the procedures for removing, installing, disassembling and assembling each com- ponent, as well as precautions for them.
MAINTENANCE STANDARD
This section gives the judgment standards for inspection of disassembled parts.
The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams.
In addition, this section may give the specifications of attachments and options together.

S.V 24/12/24