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Komatsu D85EX-15E0, D85PX-15E0 Crawler Bulldozer Shop Manual SEN00060-06 – PDF DOWNLOAD
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Description
Komatsu D85EX-15E0, D85PX-15E0 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D85EX-15E0, D85PX-15E0 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D85EX-15E0, D85PX-15E0
Serial Number: 11001 and up, 1201 and up
Book Code: SEN00060-06
Language: English
Pages: 1246
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D85EX-15E0, D85PX-15E0 Crawler Bulldozer Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-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. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu D85EX-15E0, D85PX-15E0 Crawler Bulldozer Shop Manual
COVER ............................................................................................................................................... 1 00 Index and foreword................................................................................................................................ 0 Index............................................................................................................................................ 2 Composition of shop manual................................................................................................................... 3 Table of contents............................................................................................................................ 5 Foreword and general information................................................................................................................. 16 Safety notice................................................................................................................................ 17 How to read the shop manual.................................................................................................................. 22 Explanation of terms for maintenance standard................................................................................................ 24 Handling of electric equipment and hydraulic component....................................................................................... 26 Handling of connectors newly used for engines................................................................................................ 35 How to read electric wire code............................................................................................................... 38 Precautions when carrying out operation...................................................................................................... 41 Method of disassembling and connecting push-pull type coupler................................................................................ 44 Standard tightening torque table............................................................................................................. 47 Conversion table............................................................................................................................. 51 01 Specification..................................................................................................................................... 0 Specification and technical data................................................................................................................. 58 Specification and technical data............................................................................................................. 59 Specification dimensions................................................................................................................. 59 Specifications........................................................................................................................... 60 Weight table............................................................................................................................. 68 Table of fuel, coolant and lubricants.................................................................................................... 73 10 Structure, function and maintenance standard...................................................................................................... 0 Engine and cooling system........................................................................................................................ 76 Engine and cooling system.................................................................................................................... 77 Engine mount............................................................................................................................. 77 Cooling system........................................................................................................................... 78 Cooling fan pump......................................................................................................................... 80 Cooling fan motor........................................................................................................................ 88 Power train, Part 1.......................................................................................................................... 95 Power train, Part 1...................................................................................................................... 96 Power train.......................................................................................................................... 96 HSS system........................................................................................................................... 98 General view of power train unit..................................................................................................... 100 Power train hydraulic piping drawing................................................................................................. 102 Transmission control................................................................................................................. 103 Steering and brake control........................................................................................................... 104 Damper and universal joint........................................................................................................... 106 Torque converter and PTO............................................................................................................. 108 Transmission......................................................................................................................... 114 Transmission clutch ECMV............................................................................................................. 130 Main relief valve and torque converter relief valve.................................................................................. 135 Lubrication relief valve............................................................................................................. 137 Power train, Part 2.......................................................................................................................... 139 Power train, Part 2...................................................................................................................... 140 Bevel gear shaft, HSS and brake...................................................................................................... 140 Brake valve.......................................................................................................................... 160 Final drive.......................................................................................................................... 166 Undercarriage and frame...................................................................................................................... 173 Undercarriage and frame.................................................................................................................. 174 Main frame........................................................................................................................... 174 Suspension........................................................................................................................... 176 Track frame.......................................................................................................................... 180 Idler cushion........................................................................................................................ 182 Idler................................................................................................................................ 184 Track roller......................................................................................................................... 186 Carrier roller....................................................................................................................... 188 Sprocket............................................................................................................................. 190 Track shoe........................................................................................................................... 192 Hydraulic system, Part 1..................................................................................................................... 197 Hydraulic system, Part 1................................................................................................................. 198 Work equipment hydraulic piping diagram.............................................................................................. 198 PPC control piping diagram........................................................................................................... 201 Work equipment control............................................................................................................... 202 Hydraulic tank and filter............................................................................................................ 204 Scavenging pump...................................................................................................................... 206 Power train and steering lubrication pump............................................................................................ 207 HSS pump............................................................................................................................. 208 HSS motor............................................................................................................................ 226 Hydraulic system, Part 2..................................................................................................................... 235 Hydraulic system, Part 2................................................................................................................. 236 Control valve........................................................................................................................ 236 Self pressure reducing valve......................................................................................................... 268 Hydraulic system, Part 3..................................................................................................................... 276 Hydraulic system, Part 3................................................................................................................. 277 Oil cooler bypass valve.............................................................................................................. 277 PPC valve............................................................................................................................ 279 Electric lever (steering)............................................................................................................ 294 Quick drop valve..................................................................................................................... 297 PPC lock valve....................................................................................................................... 298 Accumulator.......................................................................................................................... 299 Work equipment............................................................................................................................... 301 Work equipment........................................................................................................................... 302 Cylinder stay........................................................................................................................ 302 Blade................................................................................................................................ 303 Cutting edge and end bit............................................................................................................. 305 Ripper............................................................................................................................... 306 Hydraulic cylinder................................................................................................................... 308 Piston valve......................................................................................................................... 310 Cab and its attachments...................................................................................................................... 312 Cab and its attachments.................................................................................................................. 313 Cab mount............................................................................................................................ 313 Cab.................................................................................................................................. 314 Air conditioner...................................................................................................................... 316 Electrical system............................................................................................................................ 318 Electrical system........................................................................................................................ 319 Monitor system....................................................................................................................... 319 Monitor panel........................................................................................................................ 321 Engine control....................................................................................................................... 329 Engine control system................................................................................................................ 330 System components.................................................................................................................... 331 CRI engine control system............................................................................................................ 341 Palm command control system.......................................................................................................... 343 KOMTRAX system....................................................................................................................... 345 Sensor............................................................................................................................... 347 20 Standard value table.............................................................................................................................. 0 Standard service value table..................................................................................................................... 352 Standard service value table for engine...................................................................................................... 353 Standard service value table for chassis..................................................................................................... 354 30 Testing and adjusting............................................................................................................................. 0 Testing and adjusting, Part 1.................................................................................................................... 362 Tools for testing, adjusting, and troubleshooting............................................................................................ 364 Testing engine speed......................................................................................................................... 367 Testing intake air pressure (boost pressure)................................................................................................. 370 Testing exhaust temperature.................................................................................................................. 372 Testing exhaust gas color.................................................................................................................... 374 Adjusting valve clearance.................................................................................................................... 375 Testing compression pressure................................................................................................................. 377 Testing blow-by pressure..................................................................................................................... 379 Testing engine oil pressure.................................................................................................................. 380 Testing EGR valve and bypass valve drive oil pressure........................................................................................ 381 Handling of fuel system devices.............................................................................................................. 382 Releasing residual pressure from fuel system................................................................................................. 382 Testing fuel pressure........................................................................................................................ 383 Handling of reduced cylinder mode operation.................................................................................................. 384 Handling of no injection cranking operation.................................................................................................. 384 Testing fuel return and leak amount.......................................................................................................... 385 Bleeding air from fuel circuit............................................................................................................... 388 Testing fuel circuit for leakage............................................................................................................. 390 Testing and adjusting alternator belt tension................................................................................................ 391 Testing and adjusting air conditioner compressor belt tension................................................................................ 392 Adjusting fuel control dial and decelerator pedal............................................................................................ 393 Testing power train oil pressure............................................................................................................. 395 Adjusting transmission speed sensor.......................................................................................................... 400 Simple method to test brake performance...................................................................................................... 401 Adjusting brake pedal........................................................................................................................ 402 Adjusting parking brake lever................................................................................................................ 404 Emergency escape method when power train has trouble......................................................................................... 405 Adjusting clearance of idler................................................................................................................. 408 Inspecting wear of sprocket.................................................................................................................. 409 Testing and adjusting track shoe tension..................................................................................................... 409 Testing and adjusting work equipment and HSS oil pressure.................................................................................... 410 Testing control circuit basic pressure....................................................................................................... 414 Testing PPC valve output pressure............................................................................................................ 415 Adjusting work equipment PPC valve play...................................................................................................... 417 Checking parts which caused hydraulic drift of blade and ripper.............................................................................. 419 Testing internal leakage of work equipment cylinder.......................................................................................... 420 Bleeding air from work equipment cylinder.................................................................................................... 420 Releasing residual pressure in work equipment cylinder....................................................................................... 421 Adjusting work equipment lock lever.......................................................................................................... 422 Testing fan motor speed...................................................................................................................... 423 Testing fan pump circuit pressure............................................................................................................ 424 Bleeding air from fan pump................................................................................................................... 425 Adjusting blade.............................................................................................................................. 426 Testing and adjusting operator cab........................................................................................................... 428 Testing and adjusting, Part 2.................................................................................................................... 434 Special functions of monitor panel (EMMS).................................................................................................... 435 Testing and adjusting, Part 3.................................................................................................................... 476 Handling of voltage circuit of engine controller............................................................................................. 477 Adjustment method when controller has been replaced.......................................................................................... 477 Preparation work for troubleshooting for electrical system................................................................................... 479 Inspection procedure of diode................................................................................................................ 482 Pm Clinic service............................................................................................................................ 483 How to start operation of KOMTRAX terminal................................................................................................... 493 Lamp display of KOMTRAX terminal............................................................................................................. 497 40 Troubleshooting................................................................................................................................... 0 General information on troubleshooting........................................................................................................... 502 Points to remember when troubleshooting...................................................................................................... 503 How to proceed troubleshooting............................................................................................................... 504 Checks before troubleshooting................................................................................................................ 505 Classification and procedures of troubleshooting............................................................................................. 506 How to distinguish wire code................................................................................................................. 509 Connection table for connector pin numbers................................................................................................... 512 T- branch box and T- branch adapter table.................................................................................................... 548 Troubleshooting by failure code (Display of code), Part 1........................................................................................ 552 Failure code table........................................................................................................................... 554 Before troubleshooting by failure codes...................................................................................................... 561 Contents of troubleshooting table............................................................................................................ 563 Failure code [1500L0] Transmission clutch: Dual engagement................................................................................... 565 Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF.......................................................... 567 Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON.......................................................... 569 Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF.......................................................... 571 Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON.......................................................... 573 Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF.............................................................. 575 Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON.............................................................. 577 Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF.............................................................. 579 Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON.............................................................. 581 Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF.............................................................. 583 Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON.............................................................. 585 Failure code [AA10NX] Air cleaner: Clogged................................................................................................... 587 Failure code [AB00MA] Abnormal battery charge: Malfunction................................................................................... 589 Failure code [B@BAZG] Engine oil: Oil pressure too low....................................................................................... 589 Failure code [B@BCNS] Radiator coolant: Overheat............................................................................................. 590 Failure code [B@BCZK] Radiator coolant: Level too low........................................................................................ 590 Failure code [B@CENS] Power train oil: Overheat.............................................................................................. 591 Failure code [B@HANS] Hydraulic oil: Overheat................................................................................................ 591 Failure code [CA111] Engine controller: Abnormality in controller............................................................................ 592 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal................................................. 593 Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected...................................................... 595 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected........................................................ 597 Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected.................................................... 599 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected...................................................... 601 Failure code [CA135] Oil pressure sensor too high: Excessively high voltage detected......................................................... 603 Failure code [CA141] Oil pressure sensor too low: Excessively low voltage detected........................................................... 605 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected.................................................. 607 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected.................................................... 609 Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected................................................... 611 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected..................................................... 613 Failure code [CA187] Sensor power source 2 too low: Low voltage detected..................................................................... 615 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected................................................. 617 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected................................................... 619 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected....................................................... 621 Failure code [CA234] Engine over speed: Excessively high speed............................................................................... 623 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected............................................. 625 Failure code [CA263] Fuel temperature sensor too high: Excessively high voltage detected..................................................... 627 Failure code [CA265] Fuel temperature sensor too low: Excessively low voltage detected....................................................... 629 Failure code [CA271] PCV1 short circuit: Short circuit....................................................................................... 630 Failure code [CA272] PCV1 disconnection: Disconnection....................................................................................... 631 Failure code [CA273] PCV2 short circuit: Short circuit....................................................................................... 632 Failure code [CA274] PCV2 disconnection: Disconnection....................................................................................... 633 Troubleshooting by failure code (Display of code), Part 2........................................................................................ 636 Failure code [CA322] Injector No. 1 system disconnection or short circuit: Disconnection, short circuit...................................... 639 Failure code [CA323] Injector No. 5 system disconnection or short circuit: Disconnection, short circuit...................................... 641 Failure code [CA324] Injector No. 3 system disconnection or short circuit: Disconnection, short circuit...................................... 643 Failure code [CA325] Injector No. 6 system disconnection or short circuit: Disconnection, short circuit...................................... 645 Failure code [CA331] Injector No. 2 system disconnection or short circuit: Disconnection, short circuit...................................... 647 Failure code [CA332] Injector No. 4 system disconnection or short circuit: Disconnection, short circuit...................................... 649 Failure code [CA342] Engine controller data matching error: Matching error................................................................... 651 Failure code [CA351] Abnormal injector drive circuit: Abnormal circuit....................................................................... 653 Failure code [CA352] Sensor power source (1) too low: Excessively low voltage detected....................................................... 655 Failure code [CA386] Sensor power source (1) too high: Excessively high voltage detected..................................................... 657 Failure code [CA441] Power source voltage too low: Excessively low voltage detected.......................................................... 659 Failure code [CA442] Power source voltage too high: Excessively high voltage detected........................................................ 659 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred........................................... 660 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected................................................. 661 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected................................................... 663 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected................................................... 663 Failure code [CA554] In-range error in common rail pressure sensor: In-range error........................................................... 664 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected.............................................. 665 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal........................................................................ 669 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase................................................................. 671 Failure code [CA757] Loss of all engine controller data: Loss of all data.................................................................... 672 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal................................................................. 673 Failure code [CA1228] Abnormal EGR valve servo (1): EGR out of control....................................................................... 675 Failure code [CA1625] Abnormal EGR valve servo (2): EGR out of control....................................................................... 676 Failure code [CA1633] Abnormal KOMNET: Abnormal communication................................................................................ 677 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected...................................... 679 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected........................................ 680 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected............................................. 681 Failure code [CA2271] EGR valve lift sensor too high: Excessively high voltage detected...................................................... 683 Failure code [CA2272] EGR valve lift sensor too low: Excessively low voltage detected........................................................ 685 Failure code [CA2351] EGR valve solenoid drive short circuit: Short circuit.................................................................. 687 Failure code [CA2352] EGR valve solenoid drive disconnection: Disconnection.................................................................. 689 Failure code [CA2555] Intake air heater relay disconnection: Disconnection................................................................... 690 Failure code [CA2556] Intake air heater relay short circuit: Short circuit................................................................... 691 Troubleshooting by failure code (Display of code), Part 3........................................................................................ 694 Failure code [D110KA] Battery relay: Disconnection........................................................................................... 697 Failure code [D110KB] Battery relay: Short circuit........................................................................................... 699 Failure code [D130KA] Neutral safety relay: Disconnection.................................................................................... 701 Failure code [D130KB] Neutral safety relay: Short circuit.................................................................................... 703 Failure code [D161KA] Back-up alarm relay: Disconnection..................................................................................... 705 Failure code [D161KB] Back-up alarm relay: Short circuit..................................................................................... 707 Failure code [D190KA] Engine controller ACC signal cutout relay: Disconnection............................................................... 709 Failure code [D190KB] Engine controller ACC signal cutout relay: Short circuit............................................................... 711 Failure code [D811KR] KOMTRAX controller CAN communication: Defective communication.......................................................... 713 Failure code [DAFRKR] Monitor panel CAN communication: Defective communication............................................................... 717 Failure codes [DAQ0KT] and [DB30KT] Steering and transmission controller: Abnormal controller memory information............................. 720 Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller: Power source voltage drop and input................ 721 Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller: Power source voltage drop and input................ 723 Failure codes [DAQ5KK] and [DB35KK] Steering and transmission controller sensor 5 V power source (1): Power source voltage drop and input.... 725 Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input............ 727 Failure codes [DAQ7KK] and [DB37KK] Steering and transmission controller sensor 5 V power source (2): Power source voltage drop and input.... 729 Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection: Inconsistency in model select signal.................... 731 Failure codes [DAQRKR] and [DB3RKR] Steering and transmission controller CAN communication: Defective communication.......................... 733 Failure code [DB2RKR] Engine controller CAN communication: Defective communication........................................................... 737 Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormal controller memory information.................................. 740 Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller: Power source voltage drop and input................ 740 Failure code [DB32KK] [DAQ2KK] Load power source of steering and transmission controller: Power source voltage drop and input................ 740 Failure codes [DB35KK] and [DAQ5KK] Steering and transmission controller sensor 5 V power source (1): Power source voltage drop and input.... 740 Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input............ 740 Failure codes [DB37KK] and [DAQ7KK] Steering and transmission controller sensor 5 V power source (2): Power source voltage drop and input.... 740 Failure codes [DB39KQ] and [DAQ9KQ] Steering and transmission controller model selection: Inconsistent model selection signal................ 740 Failure codes [DB3RKR] and [DAQRKR] Steering and transmission controller CAN communication: Defective communication.......................... 740 Failure code [DD12KA] Shift up switch: Disconnection......................................................................................... 741 Failure code [DD12KB] Shift up switch: Short circuit......................................................................................... 743 Failure code [DD13KA] Shift down switch: Disconnection....................................................................................... 745 Failure code [DD13KB] Shift down switch: Short circuit....................................................................................... 747 Failure codes [DD14KA] and [DDQ2KA] Parking lock switch: Disconnection....................................................................... 749 Failure codes [DD14KB] and [DDQ2KB] Parking lock switch: Short circuit....................................................................... 751 Failure codes [DDQ2KA] and [DD14KA] Parking lock switch: Disconnection....................................................................... 753 Failure codes [DDQ2KB] and [DD14KB] Parking lock switch: Short circuit....................................................................... 753 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range.................................................. 755 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection...................................................................... 757 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range................................................ 759 Failure code [DH22KA] HSS and work equipment pump oil pressure sensor: Disconnection......................................................... 761 Failure code [DH22KB] HSS and work equipment pump oil pressure sensor: Short circuit......................................................... 763 Failure code [DK10KA] Fuel dial: Disconnection............................................................................................... 765 Failure code [DK10KB] Fuel dial: Short circuit............................................................................................... 767 Failure code [DK30KA] Steering potentiometer (1): Disconnection.............................................................................. 769 Failure code [DK30KB] Steering potentiometer (1): Short circuit.............................................................................. 771 Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range............................................................ 773 Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure)................................................ 773 Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal..................................................................... 774 Failure code [DK31KA] Steering potentiometer (2): Disconnection.............................................................................. 775 Failure code [DK31KB] Steering potentiometer (2): Short circuit.............................................................................. 777 Failure code [DK40KA] Brake potentiometer: Disconnection..................................................................................... 779 Failure code [DK40KB] Brake potentiometer: Short circuit..................................................................................... 780 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range..................................................... 781 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit (Double failure)......................................... 781 Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal.............................................................. 782 Failure code [DK56KA] Forward-reverse potentiometer (1): Disconnection....................................................................... 783 Failure code [DK56KB] Forward-reverse potentiometer (1): Short circuit....................................................................... 785 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection....................................................................... 787 Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit....................................................................... 789 Troubleshooting by failure code (Display of code), Part 4........................................................................................ 792 Troubleshooting by failure code (Display of code), Part 4.................................................................................... 794 Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit......................................................................... 794 Failure code [DKH1KB] [DKH1KX] Pitch angle sensor: Disconnection......................................................................... 795 Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range................................................ 796 Failure code [DLT3KA] Transmission output speed sensor: Disconnection.................................................................... 797 Failure code [DLT3KB] Transmission output speed sensor: Short circuit.................................................................... 798 Failure code [DV00KB] Alarm buzzer: Short circuit........................................................................................ 799 Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................................................ 800 Failure code [DW7BKB] Fan reverse solenoid: Short circuit................................................................................ 801 Failure code [DW7BKY] Fan reverse solenoid: Hot short circuit............................................................................ 802 Failure code [DWN1KA] HSS EPC solenoid right: Disconnection.............................................................................. 803 Failure code [DWN1KB] HSS EPC solenoid right: Short circuit.............................................................................. 804 Failure code [DWN1KY] HSS EPC solenoid right: Hot short circuit.......................................................................... 805 Failure code [DWN2KA] HSS EPC solenoid left: Disconnection............................................................................... 806 Failure code [DWN2KB] HSS EPC solenoid left: Short circuit............................................................................... 807 Failure code [DWN2KY] HSS EPC solenoid left: Hot short circuit........................................................................... 808 Failure code [DWN5KA] Fan pump EPC solenoid: Disconnection............................................................................... 809 Failure code [DWN5KB] Fan pump EPC solenoid: Short circuit............................................................................... 810 Failure code [DWN5KY] Fan pump EPC solenoid: Hot short circuit........................................................................... 811 Failure code [DXA0KA] HSS and work equipment pump TVC solenoid: Disconnection............................................................ 812 Failure code [DXA0KB] HSS and work equipment pump TVC solenoid: Short circuit............................................................ 813 Failure code [DXA0KY] HSS and work equipment pump TVC solenoid: Hot short circuit........................................................ 814 Failure code [DXH4KA] 1st clutch ECMV: Disconnection..................................................................................... 815 Failure code [DXH4KB] 1st clutch ECMV: Short circuit..................................................................................... 816 Failure code [DXH4KY] 1st clutch ECMV: Hot short circuit................................................................................. 817 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection..................................................................................... 818 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit..................................................................................... 819 Failure code [DXH5KY] 2nd clutch ECMV: Hot short circuit................................................................................. 820 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection..................................................................................... 821 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit..................................................................................... 822 Failure code [DXH6KY] 3rd clutch ECMV: Hot short circuit................................................................................. 823 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection................................................................................. 824 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit................................................................................. 825 Failure code [DXH7KY] Reverse clutch ECMV: Hot short circuit............................................................................. 826 Failure code [DXH8KA] Forward clutch ECMV: Disconnection................................................................................. 827 Failure code [DXH8KB] Forward clutch ECMV: Short circuit................................................................................. 828 Failure code [DXH8KY] Forward clutch ECMV: Hot short circuit............................................................................. 829 Troubleshooting of electrical system (E-mode).................................................................................................... 831 Before troubleshooting of electrical system.................................................................................................. 833 Contents of troubleshooting table............................................................................................................ 835 E-1 Engine does not start.................................................................................................................... 836 E-2 The preheater does not operate........................................................................................................... 839 E-3 The monitor panel does not light up at all when the starting switch is turned ON......................................................... 842 E-4 When the starting switch is turned ON, the monitor panel completely remains lighted and does not go out.................................. 844 E-5 When the starting switch is turned ON, the radiator coolant level caution lamp flashes................................................... 845 E-6 While the engine is running, the battery charge level caution lamp flashes............................................................... 846 E-7 While the engine is running, the emergency warning item flashes.......................................................................... 848 E-8 While the preheater is operating, the preheating pilot lamp does not light up............................................................ 850 E-9 The coolant temperature gauge does not indicate correctly................................................................................ 852 E-10 Power train oil temperature gauge does not indicate correctly........................................................................... 854 E-11 Hydraulic oil temperature gauge does not indicate properly.............................................................................. 858 E-12 Fuel gauge does not indicate properly................................................................................................... 861 E-13 Gear speed and engine speed are not indicated properly.................................................................................. 862 E-14 The preset mode and service meter do not indicate properly.............................................................................. 862 E-15 The warning lamp does not flash or does not go out...................................................................................... 863 E-16 The alarm buzzer does not sound or does not stop........................................................................................ 864 E-17 Auto shift down does not operate or does not release.................................................................................... 866 E-18 Buzzer cancel switch does not work...................................................................................................... 868 E-19 The information switch does not work.................................................................................................... 870 E-20 The manual mode does not operate or does not release.................................................................................... 872 E-21 The monitor panel cannot be set in the service mode or cannot be set out of the service mode............................................ 874 E-22 The back-up alarm does not sound........................................................................................................ 876 E-23 The head lamp and rear lamp do not light up............................................................................................. 878 E-24 The horn does not sound or does not stop................................................................................................ 881 E-25 Malfunction of wipers................................................................................................................... 882 E-26 Washer does not spray water............................................................................................................. 898 E-27 The air conditioner does not operate.................................................................................................... 903 E-28 KOMTRAX system does not operate normally................................................................................................ 908 E-29 Fan does not reverse.................................................................................................................... 910 E-30 Gear cannot be shifted.................................................................................................................. 912 Troubleshooting of hydraulic and mechanical system (H-mode)...................................................................................... 915 Troubleshooting of hydraulic and mechanical system (H-mode).................................................................................. 917 Contents of troubleshooting table........................................................................................................ 917 H-1 There is no travel power (no drawbar pull)........................................................................................... 918 H-2 Machine does not move (at 2nd or 3rd speed).......................................................................................... 919 H-3 Machine does not move at any gear speed.............................................................................................. 920 H-4 Machine travels only in one direction, forward or reverse............................................................................ 921 H-5 When gear is shifted or travel direction is changed, large time lag is made.......................................................... 922 H-6 Machine cannot be steered (Machine does not turn leftward or rightward).............................................................. 923 H-7 Steering speed or power is low....................................................................................................... 923 H-8 Brake does not work.................................................................................................................. 924 H-9 Overheat of power train oil.......................................................................................................... 925 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor....................................................... 926 H-11 All work equipment speeds are slow.................................................................................................. 927 H-12 All work equipments do not move..................................................................................................... 928 H-13 Blade lift speed is slow or lacks power............................................................................................. 928 H-14 Blade tilt speed is slow or lacks power............................................................................................. 929 H-15 Ripper lift speed is slow or lacks power............................................................................................ 929 H-16 Excessive hydraulic drift of blade lift............................................................................................. 930 H-17 Excessive hydraulic drift of blade tilt............................................................................................. 930 H-18 Excessive hydraulic drift of ripper lift............................................................................................ 931 Troubleshooting of engine (S-mode)............................................................................................................... 933 Method of using troubleshooting charts....................................................................................................... 935 S-1 Starting performance is poor............................................................................................................. 938 S-2 Engine does not start.................................................................................................................... 940 S-3 Engine does not pick up smoothly......................................................................................................... 944 S-4 Engine stops during operations........................................................................................................... 945 S-5 Engine does not rotate smoothly.......................................................................................................... 946 S-6 Engine lacks output (or lacks power)..................................................................................................... 947 S-7 Exhaust smoke is black (incomplete combustion)........................................................................................... 948 S-8 Oil consumption is excessive (or exhaust smoke is blue).................................................................................. 950 S-9 Oil becomes contaminated quickly......................................................................................................... 951 S-10 Fuel consumption is excessive........................................................................................................... 952 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down).................................................................. 953 S-12 Oil pressure drops...................................................................................................................... 954 S-13 Oil level rises (water, fuel in oil).................................................................................................... 955 S-14 Coolant temperature becomes too high (overheating)...................................................................................... 957 S-15 Abnormal noise is made.................................................................................................................. 958 S-16 Vibration is excessive.................................................................................................................. 959 50 Disassembly and assembly.......................................................................................................................... 0 General information on disassembly and assembly.................................................................................................. 961 How to read this manual...................................................................................................................... 962 Coating materials list....................................................................................................................... 964 Special tools list........................................................................................................................... 967 Sketch of special tool....................................................................................................................... 972 Engine and cooling system, Part 1................................................................................................................ 977 Removal and installation of fuel supply pump assembly........................................................................................ 978 Removal and installation of cylinder head assembly........................................................................................... 982 Removal and installation of fuel injector assembly........................................................................................... 994 Removal and installation of engine front seal................................................................................................ 999 Removal and installation of engine rear seal.................................................................................................1002 Removal and installation of engine oil pan...................................................................................................1006 Engine and cooling system, Part 2................................................................................................................1011 Removal and installation of engine assembly..................................................................................................1012 Removal and installation of radiator assembly................................................................................................1016 Removal and installation of fan drive assembly...............................................................................................1020 Removal and installation of fan motor assembly...............................................................................................1022 Removal and installation of fuel tank assembly...............................................................................................1023 Removal and installation of damper assembly..................................................................................................1025 Disassembly and assembly of damper assembly..................................................................................................1027 Removal and installation of engine hood assembly.............................................................................................1032 Power train, Part 1..............................................................................................................................1035 Removal and installation of power train unit assembly........................................................................................1036 Disconnection and connection of power train unit assembly....................................................................................1041 Disassembly and assembly of PTO assembly.....................................................................................................1045 Disassembly and assembly of torque converter assembly........................................................................................1051 Disassembly and assembly of TORQFLOW transmission assembly...................................................................................1055 Power train, Part 2..............................................................................................................................1073 Disassembly and assembly of HSS assembly.....................................................................................................1074 Removal and installation of final drive assembly.............................................................................................1093 Disassembly and assembly of final drive assembly.............................................................................................1095 Undercarriage and frame, Part 1..................................................................................................................1109 Removal and installation of track frame assembly.............................................................................................1110 Removal and installation of idler assembly...................................................................................................1113 Disassembly and assembly of idler assembly...................................................................................................1115 Removal and installation of recoil spring assembly...........................................................................................1119 Disassembly and assembly of recoil spring assembly...........................................................................................1121 Removal and installation of track roller assembly............................................................................................1125 Disassembly and assembly of track roller assembly............................................................................................1126 Removal and installation of carrier roller assembly..........................................................................................1129 Disassembly and assembly of carrier roller assembly..........................................................................................1130 Undercarriage and frame, Part 2..................................................................................................................1135 Expansion and installation of track shoe assembly............................................................................................1136 Whole disassembly and whole assembly of track shoe assembly..................................................................................1140 Field disassembly and assembly of one link...................................................................................................1153 Disassembly and assembly of master link......................................................................................................1160 Removal and installation of pivot shaft assembly.............................................................................................1163 Removal and installation of equalizer bar assembly...........................................................................................1164 Disassembly and assembly of equalizer bar assembly...........................................................................................1166 Hydraulic system.................................................................................................................................1169 Removal and installation of work equipment control valve assembly............................................................................1170 Disassembly and assembly of work equipment control valve assembly............................................................................1173 Removal and installation of HSS and work equipment pump assembly.............................................................................1174 Removal and installation of power train and lubricating oil pump assembly....................................................................1176 Removal and installation of fan pump assembly................................................................................................1177 Removal and installation of scavenging pump assembly.........................................................................................1178 Removal and installation of HSS motor assembly...............................................................................................1179 Disassembly and assembly of hydraulic cylinder assembly......................................................................................1180 Work equipment...................................................................................................................................1187 Removal and installation of blade assembly...................................................................................................1188 Disassembly and assembly of ripper assembly..................................................................................................1190 Cab and its attachments..........................................................................................................................1197 Removal and installation of ROPS guard assembly..............................................................................................1198 Removal and installation of operator’s cab assembly..........................................................................................1199 Removal and installation of operator’s cab glass (Stuck glass)...............................................................................1205 Removal and installation of floor frame assembly.............................................................................................1214 Electrical system................................................................................................................................1221 Removal and installation of engine controller................................................................................................1222 Removal and installation of steering and transmission controller.............................................................................1224 Removal and installation of KOMTRAX terminal.................................................................................................1225 90 Diagrams and drawings............................................................................................................................. 0 Hydraulic diagrams and drawings..................................................................................................................1227 Hydraulic diagrams and drawings..............................................................................................................1228 Power train hydraulic circuit diagram....................................................................................................1228 Hydraulic circuit diagram................................................................................................................1229 Electrical diagrams and drawings.................................................................................................................1232 Electrical circuit diagram...................................................................................................................1234 Cab electrical circuit diagram...............................................................................................................1242 Air conditioner electrical circuit diagram...................................................................................................1243 Connector list and stereogram................................................................................................................1244
KOMATSU D85EX-15E0, D85PX-15E0 CRAWLER BULLDOZER SHOP MANUAL SEN00060-06 – PDF DOWNLOAD:
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