Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002905

Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002905

The Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002905 provides comprehensive, factory-level technical data detailing the structure and function of essential chassis, power train, steering, and hydraulic work equipment systems. Designed for heavy equipment mechanics, field service technicians, and repair shops, this manual offers an in-depth mechanical and operational breakdown of the Komatsu D85ESS-2A crawler dozer across key serial number ranges.

File Details

• Manual Type: Shop Manual (Structure and Function)
• Machine Brand: Komatsu
• Model Covered: D85ESS-2A (D85E-SS-2A)
• Document Publication Number: SEBM002905
• Revision Date: March 2009
• Language: English
• Page Count: 906 Pages
• File Format: PDF

Chapters Covered

• Steering Brake Valve Operation and Outline (Serial No. 3001 and up, 4001 and up)
• Reducing Valve Circuit Configuration and Pressure Regulation
• Scavenging Pump Strainer Specifications and Drive Gearing
• Power Train Oil Strainer and Magnet Assembly
• Power Train Oil Filter Assembly and Relief Cracking Pressure
• Final Drive Spur and Planetary Gear Reduction Architecture
• Main Frame Hull-Structure and Unit Mounting Points
• Track Frame Construction and Track Roller Arrangement (Serial No. 3001-3033 and 3034 and up)
• Recoil Spring Assembly and Hydraulic Track Adjustment Cylinder
• Suspension Equalizer Bar Geometry and Articulation Limits
• Work Equipment Hydraulic Piping Diagrams (Angledozer Configurations)
• Work Equipment Hydraulic Piping Diagrams (Straight Tiltdozer Configurations)
• Ripper Assembly Hydraulic Circuits and Cylinder Connections
• PPC Control Piping Diagrams and Hydraulic Pilot Controls
• Work Equipment Control Levers, Safety Detents, and Lock Valves
• Work Equipment Hydraulic Circuit and System Schematic Diagrams

IMAGES PREVIEW

Together, these technical chapters provide service professionals with an exact operational roadmap for diagnosing, disassembling, and evaluating key functional systems on the crawler dozer. Rather than relying on guesswork, technicians gain direct access to original engineering drawings, fluid pathways, port designations, and baseline hydraulic pressures.

Steering, Braking, and Pressure Regulation Systems

This technical manual details the internal valving and hydraulic interactions governing steering and braking performance on the Komatsu D85ESS-2A. Sectional schematics outline the steering brake valve across serial ranges 3001 and up and 4001 and up, covering lever-actuated stroke positions, return springs, modulating springs, and internal check valves. Step-by-step fluid routing illustrations explain system behavior under four distinct operating states: when brakes are released, when the service brake pedal is depressed, when steering clutches disengage, and when the parking brake lock lever is applied. For testing and calibration, the publication specifies a balanced brake circuit pressure of 2.45 MPa (25 kg/cm²) at pressure detection port P. Additionally, the manual documents the inline reducing valve, which steps down oil pressure from the main relief valve (set at 3.2 to 3.4 MPa / 33 to 35 kg/cm² at rated speed) to a set cracking pressure of 2.5 MPa (25 kg/cm²) to safeguard steering PPC control circuits.

Power Train Filtration and Final Drive Architecture

Maintaining clean hydraulic fluid and reliable power transfer is critical for heavy earthmoving equipment. The Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002905 provides exact filtration and gearing data:

• Scavenging Pump Strainer: Driven by a 62-tooth PTO drive gear meshing with a 56-tooth pump gear; features a 100-mesh filter element with 1,520 cm² of filtering area to supply the steering lubrication circuit.
• Power Train Oil Strainer: Fitted with an integrated magnet assembly, 100-mesh wire cloth, 2,100 cm² filtering area, and a 0.2 MPa (2.0 kg/cm²) pressure resistance rating.
• Power Train Oil Filter: Employs a 30 µm filtration element with 5,400 cm² surface area, supporting a rated oil flow of 95 l/min and an internal bypass cracking pressure of 0.15 ± 0.02 MPa (1.5 ± 0.2 kg/cm²).
• Final Drive Planetary Reduction: Utilizes a single-stage spur gear and single-stage planetary gear system with splash lubrication and heavy-duty floating face seals. Detailed schematics identify tooth counts: 13-tooth sun gear, 68-tooth ring gear, 21-tooth first pinion, 78-tooth first gear, and 27-tooth planet pinions transferring torque directly to the sprocket hub.

Undercarriage, Frame, and Suspension Geometry

Complete structural drawings illustrate the robust hull-frame design where the radiator guard, main frame, and transmission underguard form a unified structure. The undercarriage section defines the track frame and suspension articulation for both early (Serial No. 3001–3033) and revised (Serial No. 3034 and up) builds. Each side utilizes 8 track rollers configured in an alternating single and double flange sequence (S, S, D, S, S, D, S, S). Detailed cross-sections explain the recoil spring assembly, including rod travel, internal piston, wear rings, and the grease lubricator valve used to adjust track shoe tension. Suspension drawings detail center pin bushings, pivot shaft seals, and equalizer bar articulation limits, establishing a maximum vertical travel of 81.9 mm upward and 81.9 mm downward at the equalizer bar side pin.

Work Equipment Hydraulics, PPC Valving, and Schematics

Extensive hydraulic circuit and piping schematics document both the Angledozer and Straight Tiltdozer arrangements, as well as multi-shank rear ripper installations. The manual outlines serial-specific changes in main hydraulic pumps, distinguishing between SAL(3)-100 pumps on machines 3001–3033 and SAL(3)-80 pumps on serial numbers 3034 and up, paired with SBR pilot pumps. Full-page schematics trace hydraulic flow through the multi-spool main control valve, highlighting load check valves, suction valves, variable unload valves, LS check valves, and back pressure check valves. Key factory pressure benchmarks include:

• Main Relief Valve Set Pressure: 20.6 MPa (210 kg/cm²)
• Main Relief Cracking Pressure: 24.5 MPa (250 kg/cm²)
• Differential Pressure: 1.8 to 2.9 MPa (18 to 30 kg/cm²)
• PPC Charge Valve Operating Pressure: 4.2 MPa (43 kg/cm²)
• Hydraulic Tank Breather Relief Cracking Pressure: 38 ± 15 kPa (0.39 ± 0.15 kg/cm²)
• Hydraulic Filter Bypass Cracking Pressure: 103 ± 20 kPa (1.05 ± 0.2 kg/cm²)

Diagnostic Capability and Immediate Digital Delivery

The Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002905 gives owners, fleet managers, and heavy equipment mechanics the precise operational data needed to troubleshoot hydraulic pressure losses, rebuild control valves, inspect final drives, and maintain track running gear. Relying on original factory engineering diagrams protects equipment from improper valve assembly, incorrect relief pressures, and premature mechanical wear. Available as an instant PDF download, this manual can be viewed immediately on laptops, desktop computers, tablets, or smartphones, and individual sections can be printed on demand for hands-on reference in the workshop or on the job site.