Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002909 PDF

Description

Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002909 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002909 – PDF DOWNLOAD 

Language : English
Pages : 1040
Downloadable : Yes
File Type : PDF

DESCRIPTION:

Komatsu D85ESS-2A Bulldozer Shop Manual SEBM002909 – PDF DOWNLOAD 

SN 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 D85ESS-2A Bulldozer Shop Manual SEBM002909 – PDF DOWNLOAD 

SN 3001 and up

COVER 1
CONTENTS 2
SAFETY 3
SAFETY NOTICE 3
FOREWORD 5
GENERAL 5
HOW TO READ THE SHOP MANUAL 6
HOISTING INSTRUCTIONS 7
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER 8
COATING MATERIALS 10
STANDARD TIGHTENING TORQUE 12
ELECTRIC WIRE CODE 15
CONVERSION TABLE 16
UNITS 22
01 GENERAL 23
GENERAL ASSEMBLY DRAWING 24
SPECIFICATIONS 26
WEIGHT TABLE 30
TABLE OF FUEL, COOLANT AND LUBRICANTS 32
10 STRUCTURE AND FUNCTION 35
RADIATOR, OIL COOLER 36
ENGINE CONTROL 38
POWER TRAIN SYSTEM 42
POWER TRAIN SKELETON 43
POWER TRAIN UNIT 44
POWER TRAIN HYDRAULIC PIPING DIAGRAM 46
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 49
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM 53
DAMPER, UNIVERSAL JOINT 55
TORQUE CONVERTER AND PTO 58
TRANSMISSION CONTROL 61
TRANSMISSION 66
TRANSMISSION CONTROL VALVE 76
MAIN RELIEF VALVE 85
LUBRICATION RELIEF VALVE 87
STEERING, BRAKE CONTROL 88
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 90
STEERING CONTROL VALVE 106
STEERING BRAKE VALVE 113
REDUCING VALVE 117
SCAVENGING PUMP STRAINER 119
POWER TRAIN OIL STRAINER 120
POWER TRAIN OIL FILTER 121
FINAL DRIVE 122
MAIN FRAME 125
TRACK FRAME 126
RECOIL SPRING 129
SUSPENSION 132
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 136
PPC CONTROL PIPING DIAGRAM 143
WORK EQUIPMENT CONTROL 146
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (ANGLEDOZER) 149
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (ANGLEDOZER) 151
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (STRAIGHT TILTDOZER) 157
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (STRAIGHT TILTDOZER) 159
HYDRAULIC TANK AND FILTER 165
PPC VALVE 174
PPC CHARGE VALVE 193
PPC LOCK VALVE 195
MAIN CONTROL VALVE 196
OPERATION OF MAIN CONTROL VALVE 203
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT 243
SUCTION VALVE 255
PISTON VALVE 261
WORK EQUIPMENT 262
ELECTRICAL CIRCUIT DIAGRAM 267
ENGINE CONTROL 283
MACHINE MONITOR SYSTEM (GAUGE TYPE PANEL) 285
MACHINE MONITOR SYSTEM (MONITOR TYPE PANEL) 293
20 TESTING AND ADJUSTING 301
STANDARD VALUE TABLE FOR ENGINE 302
STANDARD VALUE TABLE FOR CHASSIS 304
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM 312
TOOL LIST FOR TESTING AND ADJUSTING 318
ADJUSTING VALVE CLEARANCE 320
MEASURING COMPRESSION PRESSURE 321
MEASURING BLOWBY 322
ADJUSTING FUEL INJECTION TIMING 323
MEASURING EXHAUST COLOR 325
MEASURING BOOST PRESSURE 326
MEASURING EXHAUST TEMPERATURE 327
MEASURING ENGINE OIL PRESSURE 328
MEASURING ENGINE SPEED 328
TESTING FAN BELT TENSION 329
MEASURING SPEED AT TORQUE CONVERTER STALL 330
ADJUSTING FUEL CONTROL LINKAGE 332
ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE 338
ADJUSTING BRAKE PEDAL LINKAGE 345
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE 347
ADJUSTING STRAIGHT TILTDOZER 350
ADJUSTING PPC VALVE 352
MEASURING POWER TRAIN OIL PRESSURE 353
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE 360
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE 361
MEASURING OUTPUT PRESSURE OF PPC VALVE 364
MEASURING LEAKAGE INSIDE CYLINDER 366
BLEEDING AIR FROM HYDRAULIC CYLINDER 367
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT 367
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE 368
PROCEDURE FOR TESTING SENSORS 369
TESTING AND ADJUSTING OF VIBRATION STOPPER, OPEN OPEN/CLOSE LOCK OF OPERATOR’S CAB DOOR 374
ADJUSTMENT PROCEDURE FOR ENGINE COOLANT TEMPERATUREGAUGE AND POWER TRAIN OIL TEMPERATURE GAUGE 377
TROUBLESHOOTING 379
POINTS TO REMEMBER WHEN TROUBLESHOOTING 380
SEQUENCE OF EVENTS IN TROUBLESHOOTING 381
POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE 382
CHECK BEFORE TROUBLESHOOTING 390
METHOD OF USING MATRIX TROUBLESHOOTING CHARTS 392
METHOD OF USING TROUBLESHOOTING CHARTS 396
TYPE OF CONNECTOR AND POSITION OF INSTALLATION 398
CONNECTOR POSITION DRAWING 399
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 412
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM 435
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 447
S-1 Starting performance is poor (Starting always takes time) 448
S-2 Engine does not start 449
①Engine does not turn 449
②Engine turns but no exhaust gas comes out (Fuel is not being injected) 450
③Exhaust gas comes out but engine does not start (Fuel is being injected) 451
S-3 Engine does not pick up smoothly (Follow-up is poor) 452
S-4 Engine stops during operations 453
S-5 Engine does not rotate smoothly (hunting) 454
S-6 Engine lacks output (no power) 455
S-7 Exhaust gas is black (incomplete combustion) 456
S-8 Oil consumption is excessive (or exhaust gas is blue) 457
S-9 Oil becomes contaminated quickly 458
S-10 Fuel consumption is excessive 459
S-11 Oil in cooling water, or water spurts back, or water level goes down 460
S-12 Oil pressure lamp lights up (drop in oil pressure) 461
S-13 Oil level rises 462
S-14 Water temperature becomes too high (overheating) 463
S-15 Abnormal noise is made 464
S-16 Vibration is excessive 465
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE) 467
TABLE OF FAILURE MODES AND CAUSES (Hydraulic, Mechanical Systems) 469
H-1 Brake does not work 471
H-2 Machine does not turn (can travel in s straight line) 472
H-3 Overruns when turning 473
H-4 Can turn in only one direction (when steering and directional lever is operated) 474
H-5 Excessive time lag 475
H-6 Machine can travel in only one direction (forward or reverse) 475
H-7 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd) 476
H-8 Machine does not move in any speed range 478
H-9 Power train oil temperature rises too high 480
H-10 Drawbar pull is weak, travel speed is slow 482
H-11 Abnormal noise is generated from around hydraulic pump 484
H-12 Speed of all word equipment is slow 485
H-13 No work equipment moves 488
H-14 All work equipment lacks power 488
H-15 Blade lifting speed is slow or lacks power 489
H-16 Blade tilt speed is slow or lacks power 489
H-17 Hydraulic drift of blade lift is excessive 490
H-18 Hydraulic drift of blade tilt is excessive 490
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE) 491
TABLE OF FAILURE MODES AND CAUSES (Electrical System) 492
E-1 Starting motor is not cranked when starting switch is turned to ON 494
E-2 Lamps do not light up 500
a) Front lamps 500
b) Rear lamps 501
E-3 Automatic preheating is not carried out when glow switch is turned to AUTO 504
E-4 Wiper does not work 510
E-5 No washer fluid is sprayed out 512
E-6 Air conditioner has no effect 514
a) No air comes out 514
b) Does not become cool 518
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) GAUGE TYPE PANEL 523
M-1 Abnormality in engine coolant temperature gauge 524
M-2 Abnormality in power train oil temperature gauge 527
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) MONITOR TYPE PANEL 531
TABLE OF FAILURE MODES AND CAUSES (Machine Monitor System) 532
M-1 No display is given on monitor panel when starting switch is turned to ON 533
M-2 When starting switch is turned ON, all monitor panel lamps light up and do not go out 533
M-3 Preheating display is abnormal 534
a) Preheating monitor does not light up 534
b) Preheating monitor does not go out 534
M-4 CAUTION items light up or flash 540
a) (charge) lights up or flashes 540
b) When starting switch is at ON and engine is started (engine oil pressure) lights up or flashes 541
c) (coolant temperature) flashes 542
d) (power train oil temperature) flashes 544
M-5 Buzzer is abnormal 546
a) Caution item flashes but buzzer does not sound 546
b) Monitor display is normal, but buzzer sounds 546
M-6 Warning lamp is abnormal 547
a) Caution item flashing but lamp does not flash 547
b) Monitor display is normal but lamp flashes 547
M-7 Gauge is abnormal 548
a) Abnormality in engine coolant temperature gauge 548
b) Abnormality in power train oil temperature gauge 550
c) Abnormality in fuel level gauge 552
M-8 Service meter does not move after engine is started 554
M-9 Monitor panel lighting does not light up (front lamps are normal) 555
30 DISASSEMBLY AND ASSEMBLY 557
METHOD OF USING MANUAL 559
PRECAUTIONS WHEN CARRYING OUT OPERATION 560
SPECIAL TOOL LIST 562
SPECIAL TOOL SKETCH 566
STARTING MOTOR 568
REMOVAL 568
INSTALLATION 568
ALTERNATOR 569
REMOVAL 569
INSTALLATION 569
ENGINE OIL COOLER CORE 571
REMOVAL 571
INSTALLATION 571
FUEL INJECTION PUMP 572
REMOVAL 572
INSTALLATION 573
WATER PUMP 574
REMOVAL 574
INSTALLATION 574
TURBOCHAGER 577
REMOVAL 577
INSTALLATION 577
NOZZLE NOLDER 578
REMOVAL 578
INSTALLATION 578
THERMOSTAT 579
REMOVAL 579
INSTALLATION 579
CYLINDER HEAD 582
REMOVAL 582
INSTALLATION 585
ENGINE FRONT SEAL 592
REMOVAL 592
INSTALLATION 593
ENGINE REAR SEAL 594
REMOVAL 594
INSTALLATION 595
AIR COMPRESSOR 598
REMOVAL 598
INSTALLATION 598
AIR CONDENSER 599
REMOVAL 599
INSTALLATION 599
FUEL TANK 600
REMOVAL 600
INSTALLATION 601
RADIAOR 604
REMOVAL 604
INSTALLATION 606
HYDRAULIC OIL COOLER 606
REMOVAL 606
INSTALLATION 606
ENGINE (CAB SPECIFICATION) 607
REMOVAL 607
INSTALLATION 610
ENGINE (CANOPY SPESIFICATION) 615
REMOVAL 615
INSTALLATION 617
DAMPER 622
REMOVAL 622
INSTALLATION 624
POWER TRAIN UNIT 627
REMOVAL 627
INSTALLATION 633
SEPARATION 634
CONNECTION 639
TORQUE CONVERTER 640
DISASSEMBLY 640
ASSEMBLY 642
PTO 645
DISASSEMBLY 645
ASSEMBLY 648
TORQFLOW TRANSMISSION 652
DISASSEMBLY 652
ASSEMBLY 671
STEERING CASE 699
DISASSEMBLY 699
ASSEMBLY 713
TORQUE CONVERTER VALVE 738
REMOVAL 738
INSTALLATION 738
DISASSEMBLY 739
ASSEMBLY 739
TRANSMISSION CONTROL VALVE 740
REMOVAL 740
INSTALLATION 740
DISASSEMBLY 742
ASSEMBLY 742
STEERING CONTROL VALVE 746
REMOVAL 746
INSTALLATION 746
DISASSEMBLY 748
ASSEMBLY 750
REDUCING VALVE 752
REMOVAL 752
INSTALLATION 752
DISASSEMBLY 753
ASSEMBLY 753
SCAVENGING PUMP 754
REMOVAL 754
INSTALLATION 754
POWER TRAIN PUMP 755
REMOVAL 755
INSTALLATION 755
FINAL DRIVE 756
REMOVAL 756
INSTALLATION 757
DISASSEMBLY 758
ASSEMBLY 762
TRACK FRAME 768
REMOVAL 768
INSTALLATION 769
RECOIL SPRING 770
REMOVAL 770
INSTALLATION 770
DISASSEMBLY 771
ASSEMBLY 774
IDLER 780
REMOVAL 780
INSTALLATION 780
DISASSEMBLY 783
ASSEMBLY 785
TRACK ROLLER 790
REMOVAL 790
INSTALLATION 790
DISASSEMBLY 791
ASSEMBLY 792
CARRIER ROLLER 794
REMOVAL 794
INSTALLATION 795
DISASSEMBLY 796
ASSEMBLY 797
TRACK SHOE 798
REMOVAL 798
INSTALLATION 800
OVERALL DISASSEMBLY 805
OVERALL ASSEMBLY 810
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS 824
FIELD DISASSEMBLY OF ONE LINK 825
FIELD ASSEMBLY OF ONE LINK 826
PIVOT SHAFT 833
REMOVAL 833
INSTALLATION 833
EQUALIZER BAR 834
REMOVAL 834
INSTALLATION 835
EQUALIZER BAR SIDE BUSHING 836
REMOVAL 836
INSTALLATION 836
SEGMENT TEETH 837
REMOVAL 837
INSTALLATION 837
WORK EQUIPMENT PUMP 838
REMOVAL 838
INSTALLATION 838
PPC PUMP 839
REMOVAL 839
INSTALLATION 839
MAIN CONTROL VALVE 840
REMOVAL 840
INSTALLATION 840
DISASSEMBLY 842
ASSEMBLY 844
RIPPER VALVE 846
DISASSEMBLY 846
ASSEMBLY 846
MAIN RELIEF VALVE 848
REMOVAL 848
INSTALLATION 848
PPC VALVE 849
REMOVAL 849
INSTALLATION 849
DISASSEMBLY 852
ASSEMBLY 853
PPC CHARGE RELIEF VALVE 854
REMOVAL 854
INSTALLATION 854
DISASSEMBLY 855
ASSEMBLY 855
SUCTION VALVE 856
REMOVAL 856
INSTALLATION 856
BLADE LIFT CYLINDER (ANGLEDOZER) 858
REMOVAL 858
INSTALLATION 858
BLADE LIFT CYLINDER (STRAIGHT TILT DOZER) 859
REMOVAL 859
INSTALLATION 859
BLADE TILT CYLINDER 860
REMOVAL 860
INSTALLATION 860
HYDRAULIC SYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER) 861
DISASSEMBLY 861
ASSEMBLY 863
BLADE (ANGLEDOZER) 866
REMOVAL 866
INSTALLATION 867
BLADE (STRAIGHT TILT DOZER) 868
REMOVAL 868
INSTALLATION 869
DISASSEMBLY 870
ASSEMBLY 872
ROPS GUARD 874
REMOVAL 874
INSTALLATION 874
CAB 875
REMOVAL 875
INSTALLATION 876
CANOPY 877
REMOVAL 877
INSTALLATION 877
DASHBOARD (GAUGETYPE PANEL) 877
REMOVAL 877
INSTALLATION 877
DASHBOARD (MONITOR TYPE PANEL) 878
REMOVAL 878
INSTALLATION 878
PANEL (GAUGETYPE PANEL) 879
REMOVAL 879
INSTALLATION 879
PANEL (MONITOR TYPE PANEL) 880
REMOVAL 880
INSTALLATION 880
FLOOR FRAME (CANOPY SPECIFICATION) 881
REMOVAL 881
INSTALLATION 884
FLOOR FRAME (CAB SPECIFICATION) 885
REMOVAL 885
INSTALLATION 888
40 MAINTENANCE STANDARD 889
ENGINE MOUNT 890
POWER TRAIN UNIT MOUNT 891
DAMPER, UNIVERSAL JOINT 892
TORQUE CONVERTER, PTO 894
TRANSMISSION 896
TRANSMISSION CONTROL VALVE 900
MAIN RELIEF VALVE 903
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 905
STEERING CONTROL VALVE 910
STEERING BRAKE VALVE 911
POWER TRAIN, LUBRICATION PUMP 913
PPC PUMP 914
PPC VALVE 915
PPC CHARGE VALVE 922
FINAL DRIVE 924
HULL FRAME 926
TRACK FRAME, RECOIL SPRING 927
IDLER 930
TRACK ROLLER 932
CARRIER ROLLER 934
TRACK SHOE 936
SUSPENSION 940
HYDRAULIC PUMP 944
MAIN CONTROL VALVE 947
WORK EQUIPMENT CYLINDER 958
WORK EQUIPMENT 960
CUTTING EDGE, END BIT 964
RIPPER 965
90 OTHERS 967
1 GENERAL 968
1-1 SPECIFICATION 968
1-2 POWER TRAIN SYSTEM 969
2 STRUCTURE AND FUNCTION 970
2-1 GENERAL VIEW 970
2-2 WINCH SECTION 972
2-3 HYDRAULIC SYSTEM 974
2-3-1 PIPING 974
2-3-2 HYDRAULIC CIRCUIT DIAGRAM 975
2-3-3 GENERAL VIEW OF CONTROL VALVE AND FUNCTION 976
2-3-4 CLUTCH STRUCTURE AND FUNCTION (INCLUDING LUBRICATION VALVE) 978
2-4 CONTROL OF WINCH 980
2-5 FAIRLEAD 981
3 TESTING AND ADJUSTING 983
3-1 STANDARD VALUE TABLE FOR TOWING WINCH 983
3-2 TOOL LIST FOR TESTING AND ADJUSTING 984
3-3 ADJUSTING WINCH CONTROL LEVER 985
3-4 MEASURING AND ADJUSTING WINCH HYDRAULIC PRESSURE 986
3-5 TABLE OF FAILURE MODES AND CAUSES 988
H-1 Towing winch does not turn 989
H-2 Towing winch brake does not work 990
4 DISASSEMBLY AND ASSEMBLY 991
METHOD OF USING MANUAL 991
PRECAUTIONS WHEN CARRYING OUT OPERATION 992
4-1 SPECIAL TOOL LIST 994
4-2 TOWING WINCH ASSEMBLY 995
REMOVAL 995
INSTALLATION 995
4-3 TOWING WINCH PUMP ASSEMBLY 996
REMOVAL 996
INSTALLATION 996
4-4 TOWING WINCH CONTROL VALVE ASSEMBLY 997
REMOVAL 997
INSTALLATION 997
DISASSEMBLY 998
ASSEMBLY 1000
4-5 TOWING WINCH ASSEMBLY 1002
DISASSEMBLY 1002
ASSEMBLY 1015
4-6 ASSEMBLING INFORMATION 1035
4-6-1 BEARING CLEARANCE AND GEAR BACKLASH 1035
5 MAINTENANCE STANDARD 1036
5-1 CLUTCH 1036
5-2 BRAKE 1037
5-3 VALVE 1038
5-4 TOWING WINCH PUMP 1040

IMAGES PREVIEW OF THE MANUAL:

S.V  17/12/24