Komatsu Pipe Layer D85C-21 Shop Manual SEN04766-0 – PDF DOWNLOAD
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Komatsu Pipe Layer D85C-21 Shop Manual SEN04766-0 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
D85C-21 36551 and up
Description
Komatsu Pipe Layer D85C-21 Shop Manual SEN04766-0 – PDF DOWNLOAD
FILE DETAILS:
Komatsu Pipe Layer D85C-21 Shop Manual SEN04766-0 – PDF DOWNLOAD
Language : English
Pages :554
Downloadable : Yes
File Type : PDF
DESCRIPTION:
Komatsu Pipe Layer D85C-21 Shop Manual SEN04766-0 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
D85C-21 36551 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.
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.
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” to “Causes” are also included in this section.
This section explains the order to be followed when removing, installing, disassembling
or assembling each component, as well as precautions to be taken for these operations.
This section gives the judgement standards when inspecting disassembled parts.
TABLE OF CONTENTS:
Komatsu Pipe Layer D85C-21 Shop Manual SEN04766-0 – PDF DOWNLOAD
MACHINE MODEL SERIAL NUMBER
D85C-21 36551 and up
COVER 1
CONTENTS 2
01 GENERAL 0
GENERAL ASSEMBLY DRAWING 22
SPECIFICATIONS 24
WEIGHT TABLE 30
TABLE OF OIL AND COOLANT QUANTITIES 33
10 STRUCTURE AND FUNCTION 0
RADIATOR SHUTTER 38
POWER TRAIN 40
POWER TRAIN HYDRAULIC PIPING DIAGRAM 42
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM 44
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM 45
PTO 46
TORQUE CONVERTER 48
TRANSMISSION CONTROL 52
TORQFLOW TRANSMISSION 54
TRANSMISSION CONTROL VALVE 60
TRANSMISSION LUBRICATION VALVE 65
STEERING, BRAKE CONTROL 66
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE 67
STEERING MAIN LELIEF VALVE 69
STEERING AND BRAKE CONTROL VALVE 70
STEERING BRAKE 74
TRANSMISSION AND STEERING OIL STRAINER 78
TRANSMISSION AND STEERING OIL FILTER 79
FINAL DRIVE 80
TRACK GROUP 82
SUSPENSION 83
GATE FRAME 84
WINCH CONTROL 86
HYDRAULIC CIRCUIT DIAGRAM FOR WINCH 89
WINCH 90
POWER TRAIN OF WINCH 98
HIGH-LOW VALVE104
PPC VALVE105
FLOW DIVIDER VALVE107
WINCH OIL FILTER110
WINCH OIL STRAINER110
COUNTERWEIGHT HYDRAULIC TANK111
COUNTERWEIGHT PIPING112
COUNTERWEIGHT CONTROL113
HYDRAULIC CIRCUIT SCHEMATICS FOR COUNTERWEIGHT114
HYDRAULIC CIRCUIT DIAGRAM FOR COUNTERWEIGHT115
COUNTERWEIGHT116
COUNTERWEIGHT CONTROL VALVE118
BOOM119
SAFETY DEVICE120
CAB125
HEATER127
ACTUAL ELECTRICAL WIRING DIAGRAM128
ELECTRICAL CIRCUIT DIAGRAM131
20 TESTING AND ADJUSTING 0
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS138
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS141
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING145
ADJUSTING VALVE CLEARANCE146
MEASURING COMPRESSION PRESSURE147
TESTING AND ADJUSTING FUEL INJECTION TIMING148
MEASURING ENGINE OIL PRESSURE150
MEASURING EXHAUST COLOR151
MEASURING EXHAUST TEMPERATURE152
TESTING AND ADJUSTING ALTERNATOR BELT TENSION153
MEASURING BLOW-BY PRESSURE154
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)155
MEASURING ENGINE SPEED156
MEASURING TORQUE CONVERTER STALL SPEED157
BLEEDING AIR158
ADJUSTING STROKE, LINKAGE159
1 ADJUSTING FUEL CONTROL LINKAGE159
2 ADJUSTING GEAR SHIFT LEVER LINKAGE161
3 ADJUSTING STEERING LEVER LINKAGE163
4 ADJUSTING TRAVEL OF BRAKE PEDAL164
5 ADJUSTING BRAKE PEDAL LINKAGE165
6 ADJUSTING COUNTERWEIGHT CONTROL LINKAGE166
7 ADJUSTING BOOM KICKOUT CONTROL LINKAGE167
8 ADJUSTING WINCH CONTROL LINKAGE168
MEASURING POWER TRAIN OIL PRESSURE170
MEASURING COUNTERWEIGHT OIL PRESSURE172
MEASURING WINCH OIL PRESSURE173
MEASURING LEAKAGE INSIDE CYLINDER176
ADJUSTING CLEARANCE OF IDLER177
TROUBLESHOOTING179
POINTS TO REMEMBER WHEN TROUBLESHOOTING180
SEQUENCE OF EVENTS IN TROUBLESHOOTING181
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE182
CHECKS BEFORE TROUBLESHOOTING190
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)191
METHOD OF USING TROUBLESHOOTING CHARTS192
S-1 Starting performance is poor (starting always takes time)196
S-2 Engine does not start197
(1) Engine does not turn197
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)198
(3) Exhaust smoke comes out, but engine does not start (Fuel is being injected)199
S-3 Engine does not pick up smoothly200
S-4 Engine stops during operations201
S-5 Engine does not rotate smoothly (hunting)202
S-6 Engine lacks output (no power)203
S-7 Exhaust smoke is black204
S-8 Oil consumption is excessive (or exhaust smoke is blue)205
S-9 Oil becomes contaminated quickly206
S-10 Fuel consumption is excessive207
S-11 Oil is in cooling water208
S-12 Oil pressure caution lamp lights up (drop in oil pressure)209
S-13 Oil level rises (water, fuel in oil)210
S-14 Water temperature becomes too high (overheating)211
S-15 Abnormal noise is made212
S-16 Vibration is excessive213
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)215
H-1 Torque converter oil temperature is too high216
H-2 Machine does not move218
H-3 Machine lacks power or speed220
H-4 Machine moves when engine is started221
H-5 Excessive time lag when starting machine or shifting gear221
H-6 Excessive shock when starting off or shifting gear222
H-7 Machine moves in only one direction (FORWARD or REVERSE)223
H-8 Steering clutch is not disengaged224
H-9 Steering clutch slips225
H-10 Steering brake does not work226
H-11 Lack of power, speed when retract counterweight227
H-12 lmpossible to retract counterweight228
H-13 Excessive hydraulic drift of counterweight cylinder229
H-14 Defective boom RAISE, LOWER (speed, raising force, lowering force230
H-15 Defective hook RAISE, LOWER (speed, raising force, lowering force)231
H-16 Excessive hydraulic drift of boom232
H-17 Excessive hydraulic drift of hook233
H-18 Play when operating hook234
H-19 Play when operating boom235
H-20 Excessive time lag when operating hook236
H-21 Excessive time lag when operating boom237
H-22 Excessive inching amount238
H-23 Winch free fall does not work239
H-24 Winch overheats240
H-25 Excessive noise when operating winch clutch, brake241
H-26 Control lever is heavy242
30 DISASSEMBLY AND ASSEMBLY 0
METHOD OF USING MANUAL245
PRECAUTIONS WHEN CARRYING OUT OPERATION247
SPECIAL TOOL LIST249
STARTING MOTOR REMOVAL AND INSTALLATION253
ALTERNATOR REMOVAL AND INSTALLATION254
ENGINE OIL COOLER REMOVAL AND INSTALLATION255
WATER PUMP REMOVAL AND INSTALLATION256
FUEL INJECTION PUMP REMOVAL257
FUEL INJECTION PUMP INSTALLATION258
NOZZLE HOLDER REMOVAL AND INSTALLATION259
TURBOCHARGER REMOVAL AND INSTALLATION260
THERMOSTAT REMOVAL AND INSTALLATION261
ENGINE FRONT SEAL REMOVAL AND INSTALLATION262
ENGINE REAR SEAL REMOVAL263
ENGINE REAR SEAL INSTALLATION264
CYLINDER HEAD REMOVAL267
CYLINDER HEAD INSTALLATION270
RADIATOR, POWER TRAIN OIL COOLER REMOVAL AND INSTALLATION273
ENGINE REMOVAL274
ENGINE INSTALLATION278
TORQUE CONVERTER REMOVAL279
TORQUE CONVERTER INSTALLATION281
TORQUE CONVERTER DISASSEMBLY283
TORQUE CONVERTER ASSEMBLY288
TORQFLOW TRANSMISSION REMOVAL294
TORQFLOW TRANSMISSION INSTALLATION296
TORQFLOW TRANSMISSION DISASSEMBLY298
TORQFLOW TRANSMISSION ASSEMBLY309
TRANSMISSION CONTROL VALVE REMOVAL AND INSTALLATION323
TRANSMISSION CONTROL VALVE DISASSEMBLY324
TRANSMISSION CONTROL VALVE ASSEMBLY326
TRANSMISSION LUBRICATION VALVE REMOVAL AND INSTALLATION328
TRANSMISSION PUMP REMOVAL AND INSTALLATION329
BEVEL GEAR, SHAFT REMOVAL330
BEVEL GEAR, SHAFT INSTALLATION333
STEERING CLUTCH REMOVAL337
STEERING CLUTCH INSTALLATION340
STEERING CLUTCH DISASSEMBLY343
STEERING CLUTCH ASSEMBLY345
STEERING BRAKE VALVE DISASSEMBLY348
STEERING BRAKE VALVE ASSEMBLY350
FINAL DRIVE DISASSEMBLY352
FINAL DRIVE ASSEMBLY356
TRACK SHOE REMOVAL361
TRACK SHOE INSTALLATION363
TRACK FRAME REMOVAL364
TRACK FRAME INSTALLATION365
RECOIL SPRING REMOVAL366
RECOIL SPRING INSTALLATION369
RECOIL SPRING DISASSEMBLY372
RECOIL SPRING ASSEMBLY373
IDLER REMOVAL AND INSTALLATION374
TRACK ROLLER REMOVAL AND INSTALLATION375
CARRIER ROLLER REMOVAL AND INSTALLATION376
RIGHT, CENTER GATE FRAME REMOVAL377
RIGHT, CENTER GATE FRAME INSTALLATION379
COUNTERWEIGHT FRAME REMOVAL381
COUNTERWEIGHT FRAME INSTALLATION383
BOOM, LEFT GATE FRAME REMOVAL AND INSTALLATION385
WINCH DISMOUNTING386
WINCH MOUNTING388
WINCH CONTROL AND PPC VALVE DISMOUNTING AND MOUNTING390
HIGH/LOW VALVE DISMOUNTING AND MOUNTING391
WINCH DISASSEMBLY392
・ WINCH392
・ BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH418
・ BOOM BRAKE, HOOK BRAKE421
・ PPC VALVE424
・ CONTROL426
・ HI, LO SELECTOR VALVE429
・ FLOW DIVIDER VALVE431
・ STRAINER ASSEMBLY432
・ FILTER ASSEMBLY433
WINCH ASSEMBLY434
・ WINCH434
・ BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH434
・ BOOM BRAKE, HOOK BRAKE438
・ PPC VALVE ASSEMBLY441
・ CONTROL444
・ HI, LO SELECTOR VALVE447
・ FLOW DIVIDER VALVE449
・ STRAINER450
・ FILTER451
・ WINCH452
WINCH PUMP DISMOUNTING AND MOUNTING481
COUNTERWEIGHT PUMP REMOVAL AND INSTALLATION482
COUNTERWEIGHT CYLINDER REMOVAL AND INSTALLATION483
COUNTERWEIGHT CYLINDER DISASSEMBLY484
COUNTERWEIGHT CYLINDER ASSEMBLY486
COUNTERWEIGHT CONTROL VALVE REMOVAL AND INSTALLATION488
COUNTERWEIGHT CONTROL VALVE DISASSEMBLY490
COUNTERWEIGHT CONTROL VALVE ASSEMBLY492
CAUTION WHEN ASSEMBLING SHEAVE BLOCK494
CAB REMOVAL AND INSTALLATION495
40 MAINTENANCE STANDARD 0
ENGINE MOUNT498
PTO500
TORQUE CONVERTER502
TORQFLOW TRANSMISSION504
TRANSMISSION CONTROL VALVE506
TRANSMISSION LUBRICATION VALVE508
TRANSMISSION PUMP509
BEVEL GEAR SHAFT510
STEERING CLUTCH512
STEERING BRAKE514
STEERING AND BRAKE CONTROL VALVE516
STEERING MAIN RELIEF VALVE518
STEERING PUMP520
FINAL DRIVE522
TRACK FRAME524
RECOIL SPRING525
TRACK526
LDLER528
TRACK ROLLER530
CARRIER ROLLER532
SUSPENSION533
WINCH PUMP534
COUNTERWEIGHT PUMP535
HIGH-LOW VALVE536
PPC VALVE537
FLOW DIVIDER VALVE538
WINCH540
WINCH CLUTCH542
WINCH BRAKE544
COUNTERWEIGHT CONTROL VALVE546
COUNTERWEIGHT CYLINDER547
SLOW RETURN VALVE548
COUNTERWEIGHT549
BOOM, HOOK AND SHEAVE550
IMAGES PREVIEW OF THE MANUAL:
S.M 24/12/24
