Komatsu D85EX-15 D85PX-15 Bulldozer Shop Manual SEBM029114 PDF

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Komatsu D85EX-15 D85PX-15 Bulldozer Shop Manual SEBM029114 – PDF DOWNLOAD

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Komatsu D85EX-15 D85PX-15 Bulldozer Shop Manual SEBM029114 – PDF DOWNLOAD 

Language : English
Pages : 1010
Downloadable : Yes
File Type : PDF

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Komatsu D85EX-15 D85PX-15 Bulldozer Shop Manual SEBM029114 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
D85EX-15                  10001 and up
D85PX-15                   1001 and up

COVER 1
CONTENTS 2
01 GENERAL 21
SPECIFICATION DRAWING 22
SPECIFICATIONS 25
WEIGHT TABLE 36
TABLE OF FUEL, COOLANT AND LUBRICANT 38
10 STRUCTURE, FUNCTION AND MAINTENANCE STANDARD 41
POWER TRAIN 42
OVERALL DRAWING OF POWER TRAIN UNIT 44
HYDRAULIC PIPING OF POWER TRAIN 46
DAMPER, UNIVERSAL JOINT 48
TORQUE CONVERTER, PTO 50
SCAVENGING PUMP 56
TRANSMISSION CONTROL 57
TRANSMISSION 58
TRANMISSION ECMV 70
MAIN RELIEF VALVE 75
LUBRICATION RELIEF VALVE 77
POWER TRAIN PUMP, LUBRICATION PUMP 78
HSS SYSTEM 80
HYDRAULIC, HSS PUMP 82
HSS MOTOR 100
HSS OIL COOLER BYPASS VALVE 107
STEERING, BRAKE CONTROL 108
BEVEL GEAR SHAFT, HSS, BRAKE 110
BRAKE VALVE 124
FINAL DRIVE 129
SPROCKET 136
TRACK FRAME 138
RECOIL SPRING 140
IDLER 142
TRACK ROLLER 144
CARRIER ROLLER 146
TRACK SHOE 148
MAIN FRAME 152
SUSPENSION 154
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM 157
PPC CONTROL PIPING DIAGRAM 163
WORK EQUIPMENT CONTROL 164
COOLING FAN PUMP 166
COOLING FAN MOTOR 174
HYDRAULIC TANK 180
ACCUMULATOR 186
PPC LOCK VALVE 187
HYDRAULIC CYLINDER 188
PISTON VALVE 192
QUICK DROP VALVE 193
PPC VALVE 194
PCCS LEVER 208
CONTROL VALVE 212
SELF PRESSURE REDUCING VALVE 247
CYLINDER STAY 254
BLADE 256
RIPPER 261
CAB MOUNT 264
CAB 265
AIR CONDITIONER 267
ENGINE CONTROL 268
ENGINE CONTROL SYSTEM 269
DECELERATION POTENTIOMETER 270
CRI ENGINE CONTROL SYSTEM 272
MONITOR SYSTEM 274
MONITOR PANEL 277
SENSORS 284
PALM COMMAND CONTROL SYSTEM 288
20 TESTING AND ADJUSTING 291
STANDARD VALUE TABLE FOR ENGINE 292
STANDARD VALUE TABLE FOR CHASSIS 293
TESTING AND ADJUSTING 299
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING 301
MEASURING ENGINE SPEED 303
MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE) 306
MEASURING EXHAUST TEMPERATURE 308
MEASURING EXHAUST GAS COLOR 309
ADJUSTING VALVE CLEARANCE 311
MEASURING COMPRESSION PRESSURE 313
MEASURING BLOW-BY PRESSURE 315
MEASURING ENGINE OIL PRESSURE 316
HANDLING OF FUEL SYSTEM DEVICES 317
RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM 317
MEASURING FUEL PRESSURE 318
BLEEDING AIR FROM FUEL CIRCUIT 319
REDUCED CYLINDER MODE OPERATION FOR ENGINE 322
TESTING AND ADJUSTING ALTERNATOR BELT TENSION 323
TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION 323
ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL 324
MEASURING POWER TRAIN OIL PRESSURE 326
ADJUSTING TRANSMISSION SPEED SENSOR 332
SIMPLE METHOD OF TESTING BRAKE PERFORMANCE 333
ADJUSTING BRAKE PEDAL 334
EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE 337
ADJUSTING CLEARANCE OF IDLER 340
INSPECTING WEAR OF SPROCKET 341
TESTING AND ADJUSTING TRACK SHOE TENSION 341
TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE 342
TESTING CONTROL CIRCUIT MAIN PRESSURE 345
MEASURING PPC VALVE OUTPUT PRESSURE 346
ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE 348
TESTING PARTS WHICH CAUSE HYDRAULIC DRIFT OF BLADE AND RIPPER 349
MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER 350
BLEEDING AIR FROM WORK EQUIPMENT CYLINDER 350
RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER 351
ADJUSTING SAFETY LOCK LEVER 352
MEASURING FAN MOTOR SPEED 353
MEASURING FAN PUMP CIRCUIT PRESSURE 354
BLEEDING AIR FROM FAN PUMP 357
ADJUSTING BLADE 358
TESTING AND ADJUSTING OF OPERATOR’S CAB 360
SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS) 364
HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER 409
ADJUSTMENT METHOD OF REPLACED CONTROLLER 409
PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM 411
Pm CLINIC SERVICE 413
UNDERCARRIAGE TROUBLESHOOTING REPORT 422
TROUBLESHOOTING 425
POINTS TO REMEMBER WHEN TROUBLESHOOTING 426
SEQUENCE OF EVENTS IN TROUBLESHOOTING 427
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE 428
CHECKS BEFORE TROUBLESHOOTING 436
CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING 437
TYPES AND LOCATIONS OF CONNECTORS 440
CONNECTOR ARRANGEMENT DRAWING 446
CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT) 454
CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (ST • TM CIRCUIT) 456
CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT) 458
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS 460
T-BRANCH BOX AND T-BRANCH TABLE 483
TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE) 485
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 489
TROUBLE CODE TABLE 490
ERROR CODE 1500LO (TRANSMISSION CLUTCH: SEE THE LIST (L1)) 491
ERROR CODE 15SAL1 (FORWARD CLUTCH: SEE THE LIST (L1)) 492
ERROR CODE 15SALH (FORWARD CLUTCH: SEE THE LIST (LH)) 493
ERROR CODE 15SBL1 (REVERSE CLUTCH: SEE THE LIST (L1)) 494
ERROR CODE 15SBLH (REVERSE CLUTCH: SEE THE LIST (LH)) 495
ERROR CODE 15SEL1 (1ST CLUTCH: SEE THE LIST (L1)) 496
ERROR CODE 15SELH (1ST CLUTCH: SEE THE LIST (LH)) 497
ERROR CODE 15SFL1 (2ND CLUTCH: SEE THE LIST (L1)) 498
ERROR CODE 15SFLH (2ND CLUTCH: SEE THE LIST (LH)) 499
ERROR CODE 15SGL1 (3RD CLUTCH: SEE THE LIST (L1)) 500
ERROR CODE 15SGLH (3RD CLUTCH: SEE THE LIST (LH)) 501
ERROR CODE A000N1 (ENGINE: OVERRUN (N1)) 502
ERROR CODE AB00MA (ALTERNATOR: MALFUNCTION (MA)) 503
ERROR CODE AD00L2 (COMMON RAIL: SEE THE LIST (L2)) 503
ERROR CODE AD00MA (COMMON RAIL: DEFECTIVE FUNCTION (MA)) 504
ERROR CODE AD10L3 (FUEL SUPPLY PUMP: SEE THE LIST (L3)) 504
ERROR CODE AD10MA (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA)) 507
ERROR CODE AD10MB (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB)) 507
ERROR CODE AD11KA (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION INWIRING (KA)) 508
ERROR CODE AD11KB (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB)) 509
ERROR CODE AD51KA (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION INWIRING (KA)) 510
ERROR CODE AD51KB (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION INSHORT (KB)) 511
ERROR CODE ADA1KA (NO 1 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA)) 512
ERROR CODE ADAZKB (NO 1, 2, AND 3 INJECTOR SOLENOIDS: SHORT (KB)) 513
ERROR CODE ADB1KA (NO 2 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA)) 515
ERROR CODE ADC1KA (NO 3 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA)) 516
ERROR CODE ADD1KA (NO 4 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA)) 517
ERROR CODE ADDZKB (NO 4, 5, AND 6 INJECTOR SOLENOIDS: SHORT (KB)) 518
ERROR CODE ADE1KA (NO 5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA)) 520
ERROR CODE ADF1KA (NO 6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA)) 521
ERROR CODE B@BAZG (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)) 522
ERROR CODE B@BCNS (RADIATOR COOLANT: OVERHEAT (NS)) 522
ERROR CODE B@BCZK (RADIATOR COOLANT: LEVEL REDUCTION (ZK)) 523
ERROR CODE B@CENS (POWER TRAN OIL: OVERHEAT (NS)) 523
ERROR CODE B@HANS (HYDRAULIC OIL: OVERHEAT (NS)) 524
ERROR CODE D110KA (BATTERY RELAY: DISCONNECTION (KA)) 525
ERROR CODE D110KB (BATTERY RELAY: SHORT CIRCUIT (KB)) 526
ERROR CODE D130KA (NEUTRAL SAFETY RELAY: DISCONNECTION (KA)) 527
ERROR CODE D130KB (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KB)) 529
ERROR CODE D161KA (BACK-UP ALARM RELAY: DISCONNECTION (KA)) 530
ERROR CODE D161KB (BACK-UP ALARM RELAY: SHORT CIRCUIT (KB)) 532
ERROR CODE D182KZ (PREHEATER RELAY COIL: DISCONNECTION OR SHORT CIRCUIT) (KZ) 534
ERROR CODE D1D0KB (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY: SHORT CIRCUIT (KB)) 536
ERROR CODE D5ZFKA (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION) (KA) 538
ERROR CODE D5ZFKB (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT) (KB) 539
ERROR CODE DAFRKR (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 540
ERROR CODE DAQ0KK DB30KK (STEERING AND TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 542
ERROR CODE DAQ0KT DB30KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 543
ERROR CODE DAQ5KK DB35KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 544
ERROR CODE DAQ6KK DB36KK (STEERING AND TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 546
ERROR CODE DAQ9KQ DB39KQ (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 547
ERROR CODE DAQRKR DB3RKR (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 548
ERROR CODE DB20KQ (ENGINE CONTROLLER TYPE COLLATION: TYPE SELECT CODE INCONSISTENCY (KQ)) 550
ERROR CODE DB20KT (ENGINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 552
ERROR CODE DB22KK (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 553
ERROR CODE DB29KQ (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 555
ERROR code DB2AMA (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL: MALFUNCTION (MA)) 556
ERROR CODE DB2RKR (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 557
ERROR CODE DB2RMC (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (MC)) 559
ERROR CODE DB30KK DAQ0KK (STEERING AND TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 561
ERROR CODE DB30KT DAQ0KT (STEERING AND TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)) 561
ERROR CODE DB35KK DAQ5KK (STEERING AND TRANSMISSION CONTROLLER ENSOR 5V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 561
ERROR CODE DB36KK DAQ6KK (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)) 561
ERROR CODE DB39KQ DAQ9KQ (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)) 561
ERROR CODE DB3RKR DAQRKR (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)) 561
ERROR CODE DD11KB (STARTING SWITCH: SHORT CIRCUIT (KB)) 562
ERROR CODE DD12KA (SHIFT UP SWITCH: DISCONNECTION (KA)) 563
ERROR CODE DD12KB (SHIFT UP SWITCH: SHORT CIRCUIT (KB)) 565
ERROR CODE DD13KA (SHIFT DOWN SWITCH: DISCONNECTION (KA)) 567
ERROR CODE DD13KB (SHIFT DOWN SWITCH: SHORT CIRCUIT (KB)) 569
ERROR CODE DD14KA DDQ2KA (PARKING LEVER SWITCH: DISCONNECTION (KA)) 571
ERROR CODE DD14KB DDQ2KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) 573
ERROR CODE DDE2L6 (ENGINE OIL PRESSURE SWITCH: REFER TO TABLE (L6) 575
ERROR CODE DDQ2KA DD14KA (PARKING LEVER SWITCH: DISCONNECTION (KA)) 577
ERROR CODE DDQ2KB DD14KB (PARKING LEVER SWITCH: SHORT CIRCUIT (KB)) 577
ERROR CODE DGE2KX (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 578
ERROR CODE DGE3L6 (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE): SEE TABLE (L6)) 579
ERROR CODE DGE4KX (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 580
ERROR CODE DGS1KX (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 581
ERROR CODE DH21KA (HSS AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: DISCONNECTION (KA)) 582
ERROR CODE DH21KB (HSS AND WORK EQUIPMENT PUMP OIL PRESSURE SENSOR: SHORT CIRCUIT (KB)) 583
ERROR CODE DH30KX (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX)) 584
ERROR CODE DH40KX (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX)) 586
ERROR CODE DK10KX (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX)) 588
ERROR CODE DK12KX (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE (KX)) 590
ERROR CODE DK30KA (STEERING POTENTIOMETER 1: DISCONNECTION (KA)) 592
ERROR CODE DK30KB (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)) 594
ERROR CODE DK30KX (STEERING POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 595
ERROR CODE DK30KZ (STEERING POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (Double trouble) (KZ)) 595
ERROR CODE DK30L8 (STEERING POTENTIOMETER 1: SEE TABLE (L8)) 596
ERROR CODE DK31KA (STEERING POTENTIOMETER 2: DISCONNECTION (KA)) 597
ERROR CODE DK31KB (STEERING POTENTIOMETER 2: SHORT CIRCUIT (KB)) 599
ERROR CODE DK40KA (BRAKE POTENTIOMETER: DISCONNECTION (KA)) 600
ERROR CODE DK40KB (BRAKE POTENTIOMETER: SHORT CIRCUIT (KB)) 602
ERROR CODE DK55KX (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)) 603
ERROR CODE DK55KZ (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (KZ)) 603
ERROR CODE DK55L8 (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8)) 604
ERROR CODE DK56KA (FORWARD-REVERSE POTENTIOMETER 1: DISCONNECTION (KA)) 605
ERROR CODE DK56KB (FORWARD-REVERSE POTENTIOMETER 1: SHORT CIRCUIT (KB)) 607
ERROR CODE DK57KA (FORWARD-REVERSE POTENTIOMETER 2: DISCONNECTION (KA)) 608
ERROR CODE DK57KB (FORWARD-REVERSE POTENTIOMETER 2: SHORT CIRCUIT (KB)) 610
ERROR CODE DKH1KA (PITCH ANGLE SENSOR: DISCONNECTION (KA)) 611
ERROR CODE DKH1KB (PITCH ANGLE SENSOR: SHORT CIRCUIT (KB)) 612
ERROR CODE DLE3LC (ENGINE NE SPEED SENSOR: SEE TABLE (LC)) 613
ERROR CODE DLF1KA (TRANSMISSION BEVEL SPEED SENSOR: DISCONNECTION (KA)) 615
ERROR CODE DLH1LC (ENGINE G SPEED SENSOR: SEE TABLE (LC)) 616
ERROR CODE DV00KB (CAUTION BUZZER: SHORT CIRCUIT (KB)) 617
ERROR CODE DW7BKA (FAN REVERSE SOLENOID: DISCONNECTION (KA)) 620
ERROR CODE DW7BKB (FAN REVERSE SOLENOID: SHORT CIRCUIT (KB)) 621
ERROR CODE DWN1KA (HSS EPC SOLENOID LEFT: DISCONNECTION (KA)) 622
ERROR CODE DWN1KB (HSS EPC SOLENOID LEFT: SHORT CIRCUIT (KB)) 623
ERROR CODE DWN2KA (HSS EPC SOLENOID RIGHT: DISCONNECTION (KA)) 624
ERROR CODE DWN2KB (HSS EPC SOLENOID RIGHT: SHORT CIRCUIT (KB)) 625
ERROR CODE DWN5KA (FAN PUMP SOLENOID: DISCONNECTION (KA)) 626
ERROR CODE DWN5KB (FAN PUMP SOLENOID: SHORT CIRCUIT (KB)) 627
ERROR CODE DXA0KA (HSS • HYDRAULIC PUMP TVC SOLENOID: DISCONNECTION (KA)) 628
ERROR CODE DXA0KB (HSS • HYDRAULIC PUMP TVC SOLENOID: SHORT CIRCUIT (KB)) 629
ERROR CODE DXH4KA (1ST CLUTCH ECMV: DISCONNECTION (KA)) 630
ERROR CODE DXH4KB (1ST CLUTCH ECMV: SHORT CIRCUIT (KB)) 631
ERROR CODE DXH5KA (2ND CLUTCH ECMV: DISCONNECTION (KA)) 632
ERROR CODE DXH5KB (2ND CLUTCH ECMV: SHORT CIRCUIT (KB)) 633
ERROR CODE DXH6KA (3RD CLUTCH ECMV: DISCONNECTION (KA)) 634
ERROR CODE DXH6KB (3RD CLUTCH ECMV: SHORT CIRCUIT (KB)) 635
ERROR CODE DXH7KA (REVERSE CLUTCH ECMV: DISCONNECTION (KA)) 636
ERROR CODE DXH7KB (REVERSE CLUTCH ECMV: SHORT CIRCUIT (KB)) 637
ERROR CODE DXH8KA (FORWARD CLUTCH ECMV: DISCONNECTION (KA)) 638
ERROR CODE DXH8KB (FORWARD CLUTCH ECMV: SHORT CIRCUIT (KB)) 639
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE) 641
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 642
E-1 THE ENGINE DOES NOT START 643
E-2 THE PREHEATER DOES NOT OPERATE (MANUAL PREHEATING FUNCTION) 645
E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH IS TURNED ON 647
E-4 WHEN THE STARTING SWITCH IS TURNED ON, THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT 648
E-5 WHEN THE STARTING SWITCH IS TURNED ON, THE RADIATOR WATER LEVEL CAUTION LAMP FLASHES 649
E-6 WHILE THE ENGINE IS OPERATING, THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES 650
E-7 WHILE THE ENGINE IS OPERATING, THE EMERGENCY WARNING ITEM FLASHES 652
E-8 WHILE THE PREHEATER IS OPERATING, THE PREHEATING PILOT LAMP DOES NOT COME ON 657
E-9 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 659
E-10 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL 660
E-11 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY 661
E-12 INDICATION OF THE FUEL GAUGE IS ABNORMAL 662
E-13 INDICATIONS OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL 663
E-14 INDICATION OF THE PRESET MODE SERVICE METER IS ABNORMAL 663
E-15 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT 664
E-16 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP 665
E-17 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED 668
E-18 THE BUZZER CANCEL SWITCH DOES NOT WORK 669
E-19 THE INFORMATION SWITCH DOES NOT WORK 670
E-20 THE MANUAL MODE DOES NOT OPERATE OR CANNOT BE RESET 672
E-21 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE 673
E-22 THE BACK-UP ALARM DOES NOT SOUND 675
E-23 THE HEAD LAMP, REAR LAMP, AND RIPPER POINT LAMP DO NOT LIGHT UP 676
E-24 MALFUNCTION OF WIPERS 679
E-25 WASHING WATER DOES NOT COME OUT 695
E-26 THE AIR CONDITIONER DOES NOT OPERATE 700
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE) 705
INFORMATION DESCRIBED IN TROUBLESHOOTING LIST 706
H-1 NO TRAVEL POWER (NO DRAWBAR PULL) 707
H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED) 708
H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE 709
H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE 710
H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED, LARGE TIME LAG IS MADE 711
H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD) 712
H-7 STEERING SPEED OR POWER IS LOW 712
H-8 BRAKE DOES NOT WORK 713
H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATUR 713
H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR 714
H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW 714
H-12 WORK EQUIPMENT DOES NOT MOVE 715
H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWER 715
H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER 716
H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER 716
H-16 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT 717
E-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT 717
H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT 718
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE) 719
METHOD OF USING TROUBLESHOOTING CHARTS 720
S-1 Starting performance is poor (starting always takes time) 724
S-2 Engine does not start 725
S-3 Engine does not pick up smoothly (follow-up is poor) 728
S-4 Engine stops during operations 729
S-5 Engine does not rotate smoothly (hunting) 730
S-6 Engine lacks output (or lacks power) 731
S-7 Exhaust smoke is black (incomplete combustion) 732
S-8 Oil consumption is excessive (or exhaust smoke is blue) 733
S-9 Oil becomes contaminated quickly 734
S-10 Fuel consumption is excessive 735
S-11 Oil is in cooling water (or water spurts back, or water level goes down) 736
S-12 Oil pressure caution lamp lights up (drop in oil pressure) 737
S-13 Oil level rises (water, fuel in oil) 738
S-14 Water temperature becomes too high (overheating) 739
S-15 Abnormal noise is made 740
S-16 Vibration is excessive 741
30 DISASSEMBLY AND ASSEMBLY 743
HOW TO READ THIS MANUAL 745
PRECAUTIONS WHEN PERFORMING OPERATION 747
SPECIAL TOOL LIST 749
SKETCH OF SPECIAL TOOL 755
FUEL SUPPLY PUMP 759
SPECIAL TOOLS 759
REMOVAL 759
INSTALLATION 762
FUEL INJECTOR 765
REMOVAL 765
INSTALLATION 766
NOZZLE TIP 769
SPECIAL TOOL 769
REMOVAL 769
INSTALLATION 770
ENGINE FRONT SEAL 771
SPECIAL TOOLS 771
REMOVAL 771
INSTALLATION 772
ENGINE REAR SEAL 773
SPECIAL TOOLS 773
REMOVAL AND INSTALLATION 773
ENGINE CYLINDER HEAD 776
SPECIAL TOOLS 776
REMOVAL 776
INSTALLATION 781
ENGINE OIL PAN 784
REMOVAL 784
INSTALLATION 786
FUEL TANK 787
REMOVAL 787
INSTALLATION 788
RADIATOR 789
REMOVAL 789
INSTALLATION 790
ENGINE 791
SPECIAL TOOLS 791
REMOVAL 791
INSTALLATION 794
DAMPER 795
REMOVAL 795
INSTALLATION 796
SPECIAL TOOLS 797
DISASSEMBLY 798
ASSEMBLY 800
POWER TRAIN UNIT 802
REMOVAL 802
INSTALLATION 805
DISCONNECTION 806
CONNECTION 809
TORQFLOW TRANSMISSION 810
SPECIAL TOOLS 810
DISASSEMBLY 810
ASSEMBLY 816
HSS 824
SPECIAL TOOLS 824
DISASSEMBLY 824
ASSEMBLY 831
PTO 842
DISASSEMBLY 842
ASSEMBLY 844
TORQUE CONVERTER 848
DISASSEMBLY 848
ASSEMBLY 849
SCAVENGING PUMP 852
REMOVAL AND INSTALLATION 852
HSS AND WORK EQUIPMENT PUMP 853
REMOVAL 853
INSTALLATION 854
FAN PUMP 855
REMOVAL AND INSTALLATION 855
POWER TRAIN AND LUBRICATING OIL PUMP 856
REMOVAL AND INSTALLATION 856
HSS MOTOR 857
REMOVAL AND INSTALLATION 857
FINAL DRIVE 858
SPECIAL TOOLS 858
REMOVAL 858
INSTALLATION 859
SPECIAL TOOLS 860
DISASSEMBLY 860
ASSEMBLY 865
TRACK FRAME 872
REMOVAL 872
INSTALLATION 874
IDLER 875
REMOVAL AND INSTALLATION 875
SPECIAL TOOLS 877
DISASSEMBLY 877
ASSEMBLY 878
RECOIL SPRING 881
REMOVAL 881
INSTALLATION 882
SPECIAL TOOLS 883
DISASSEMBLY 883
ASSEMBLY 885
TRACK ROLLER 887
REMOVAL AND INSTALLATION 887
SPECIAL TOOLS 888
DISASSEMBLY 888
ASSEMBLY 889
CARRIER ROLLER 891
REMOVAL AND INSTALLATION 891
SPECIAL TOOLS 892
DISASSEMBLY 892
ASSEMBLY 893
TRACK SHOE 895
CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY 895
EXPANSION OF TRACK SHOE ASSEMBLY (Ordinary) 895
EXPANSION OF TRACK SHOE ASSEMBLY (When track frame has internal trouble) 896
INSTALLATION 897
SPECIAL TOOLS 898
WHOLE DISASSEMBLY 898
WHOLE ASSEMBLY 900
DIMENSIONS TABLE OF FITTING JIG OF LINK PRESS 911
DISASSEMBLY AND ASSEMBLY OF 1 LINK IN THE FIELD 912
DISASSEMBLY AND ASSEMBLY OF MASTER LINK 914
PIVOT SHAFT 917
REMOVAL AND INSTALLATION 917
EQUALIZER BAR 918
REMOVAL 918
INSTALLATION 919
DISASSEMBLY AND ASSEMBLY 920
CENTER UNDER GUARD 922
OPEN AND CLOSE 922
REMOVAL AND INSTALLATION 925
WORK EQUIPMENT CONTROL VALVE 936
REMOVAL 936
INSTALLATION 938
ASSEMBLY 939
HYDRAULIC CYLINDER 940
SPECIAL TOOLS 940
DISASSEMBLY 940
ASSEMBLY 943
BLADE 945
REMOVAL 945
INSTALLATION 946
BLADE LIFT CYLINDER 947
Removal 948
Installation 952
RIPPER 955
DISASSEMBLY 955
ASSEMBLY 957
ROPS GUARD 959
REMOVAL AND INSTALLATION 959
OPERATOR’S CAB 960
REMOVAL 960
INSTALLATION 962
OPERATOR’S CAB GLASS (STUCK GLASS) 966
SPECIAL TOOLS 967
REMOVAL 967
INSTALLATION 968
FLOOR FRAME 975
SPECIAL TOOLS 975
REMOVAL 975
INSTALLATION 978
ENGINE CONTROLLER 980
REMOVAL AND INSTALLATION 980
STEERING AND TRANSMISSION CONTROLLER 981
REMOVAL AND INSTALLATION 981
ENGINE HOOD 982
REMOVAL AND INSTALLATION 982
FAN DRIVE 983
REMOVAL 983
INSTALLATION 984
FAN MOTOR 985
REMOVAL AND INSTALLATION 985
90 OTHERS 987
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 989
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (1/3) 991
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (2/3) 993
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (3/3) 995
ELECTRICAL CIRCUIT DIAGRAM (1/6) 997
ELECTRICAL CIRCUIT DIAGRAM (2/6) 999
ELECTRICAL CIRCUIT DIAGRAM (3/6) 1001
ELECTRICAL CIRCUIT DIAGRAM (4/6) 1003
ELECTRICAL CIRCUIT DIAGRAM (5/6) 1005
ELECTRICAL CIRCUIT DIAGRAM (6/6) 1007
CAB ELECTRICAL CIRCUIT DIAGRAM 1009

DESCRIPTION:

Komatsu D85EX-15 D85PX-15 Bulldozer Shop Manual SEBM029114 – PDF DOWNLOAD 

MACHINE MODEL   SERIAL NUMBER
D85EX-15                  10001 and up
D85PX-15                   1001 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 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. For ease of understanding, the manual is divided into the following chapters; these chapters are further
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 understanding
of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance
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 component,
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 29/12/24