Komatsu D85C-21 PipeLayer Shop Manual SEN04766-00

Description

• Model List:
  • D85C-21 PipeLayer

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. TABLE OF OIL AND COOLANT QUANTITIES
• 4. STRUCTURE AND FUNCTION
• 4.1. RADIATOR SHUTTER
• 4.2. POWER TRAIN
• 4.3. POWER TRAIN HYDRAULIC PIPING DIAGRAM
• 4.4. POWER TRAIN HYDRAULIC SYSTEM DIAGRAM
• 4.5. POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
• 4.7. TORQUE CONVERTER
• 4.8. TRANSMISSION CONTROL
• 4.9. TORQFLOW TRANSMISSION
• 4.10. TRANSMISSION CONTROL VALVE
• 4.11. TRANSMISSION LUBRICATION VALVE
• 4.12. STEERING, BRAKE CONTROL
• 4.13. BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
• 4.14. STEERING MAIN LELIEF VALVE
• 4.15. STEERING AND BRAKE CONTROL VALVE
• 4.16. STEERING BRAKE
• 4.17. TRANSMISSION AND STEERING OIL STRAINER
• 4.18. TRANSMISSION AND STEERING OIL FILTER
• 4.19. HYDRAULIC CIRCUIT DIAGRAM FOR WINCH
• 4.20. WINCH
• 4.21. POWER TRAIN OF WINCH
• 4.22. HIGHLOW VALVE
• 4.23. PPC VALVE
• 4.24. FLOW DIVIDER VALVE
• 4.25. WINCH OIL FILTER
• 4.26. WINCH OIL STRAINER
• 4.27. COUNTERWEIGHT HYDRAULIC TANK
• 4.28. COUNTERWEIGHT PIPING
• 4.29. COUNTERWEIGHT CONTROL
• 4.30. HYDRAULIC CIRCUIT SCHEMATICS FOR COUNTERWEIGHT
• 4.31. HYDRAULIC CIRCUIT DIAGRAM FOR COUNTERWEIGHT
• 4.32. COUNTERWEIGHT
• 4.33. COUNTERWEIGHT CONTROL VALVE
• 4.34. BOOM
• 4.35. SAFETY DEVICE
• 4.37. HEATER
• 4.38. ACTUAL ELECTRICAL WIRING DIAGRAM
• 4.39. ELECTRICAL CIRCUIT DIAGRAM
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
• 5.2. STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
• 5.3. TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
• 5.4. ADJUSTING VALVE CLEARANCE
• 5.5. MEASURING COMPRESSION PRESSURE
• 5.6. TESTING AND ADJUSTING FUEL INJECTION TIMING
• 5.7. MEASURING ENGINE OIL PRESSURE
• 5.8. MEASURING EXHAUST COLOR
• 5.9. MEASURING EXHAUST TEMPERATURE
• 5.10. TESTING AND ADJUSTING ALTERNATOR BELT TENSION
• 5.11. MEASURING BLOWBY PRESSURE
• 5.12. MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
• 5.13. MEASURING ENGINE SPEED
• 5.14. MEASURING TORQUE CONVERTER STALL SPEED
• 5.15. BLEEDING AIR
• 5.16. ADJUSTING STROKE, LINKAGE
• 5.16.1. ADJUSTING FUEL CONTROL LINKAGE
• 5.16.2. ADJUSTING GEAR SHIFT LEVER LINKAGE
• 5.16.3. ADJUSTING STEERING LEVER LINKAGE
• 5.16.4. ADJUSTING TRAVEL OF BRAKE PEDAL
• 5.16.5. ADJUSTING BRAKE PEDAL LINKAGE
• 5.16.6. ADJUSTING COUNTERWEIGHT CONTROL LINKAGE
• 5.16.7. ADJUSTING BOOM KICKOUT CONTROL LINKAGE
• 5.16.8. ADJUSTING WINCH CONTROL LINKAGE
• 5.17. MEASURING POWER TRAIN OIL PRESSURE
• 5.18. MEASURING COUNTERWEIGHT OIL PRESSURE
• 5.19. MEASURING WINCH OIL PRESSURE
• 5.20. MEASURING LEAKAGE INSIDE CYLINDER
• 5.21. ADJUSTING CLEARANCE OF IDLER
• 5.22. TROUBLESHOOTING
• 5.22.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.22.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.22.3. POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 5.22.4. CHECKS BEFORE TROUBLESHOOTING
• 5.22.5. TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
• 5.22.6. TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
• 6. DISASSEMBLY AND ASSEMBLY
• 6.1. METHOD OF USING MANUAL
• 6.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 6.3. SPECIAL TOOL LIST
• 6.4. STARTING MOTOR REMOVAL AND INSTALLATION
• 6.5. ALTERNATOR REMOVAL AND INSTALLATION
• 6.6. ENGINE OIL COOLER REMOVAL AND INSTALLATION
• 6.7. WATER PUMP REMOVAL AND INSTALLATION
• 6.8. FUEL INJECTION PUMP REMOVAL
• 6.9. FUEL INJECTION PUMP INSTALLATION
• 6.10. NOZZLE HOLDER REMOVAL AND INSTALLATION
• 6.11. TURBOCHARGER REMOVAL AND INSTALLATION
• 6.12. THERMOSTAT REMOVAL AND INSTALLATION
• 6.13. ENGINE FRONT SEAL REMOVAL AND INSTALLATION
• 6.14. ENGINE REAR SEAL REMOVAL
• 6.15. ENGINE REAR SEAL INSTALLATION
• 6.16. CYLINDER HEAD REMOVAL
• 6.17. CYLINDER HEAD INSTALLATION
• 6.18. RADIATOR, POWER TRAIN OIL COOLER REMOVAL AND INSTALLATION
• 6.19. ENGINE REMOVAL
• 6.20. ENGINE INSTALLATION
• 6.21. TORQUE CONVERTER REMOVAL
• 6.22. TORQUE CONVERTER INSTALLATION
• 6.23. TORQUE CONVERTER DISASSEMBLY
• 6.24. TORQUE CONVERTER ASSEMBLY
• 6.25. TORQFLOW TRANSMISSION REMOVAL
• 6.26. TORQFLOW TRANSMISSION INSTALLATION
• 6.27. TORQFLOW TRANSMISSION DISASSEMBLY
• 6.28. TORQFLOW TRANSMISSION ASSEMBLY
• 6.29. TRANSMISSION CONTROL VALVE REMOVAL AND INSTALLATION
• 6.30. TRANSMISSION CONTROL VALVE DISASSEMBLY
• 6.31. TRANSMISSION CONTROL VALVE ASSEMBLY
• 6.32. TRANSMISSION LUBRICATION VALVE REMOVAL AND INSTALLATION
• 6.33. TRANSMISSION PUMP REMOVAL AND INSTALLATION
• 6.34. BEVEL GEAR, SHAFT REMOVAL
• 6.35. BEVEL GEAR, SHAFT INSTALLATION
• 6.36. STEERING CLUTCH REMOVAL
• 6.37. STEERING CLUTCH INSTALLATION
• 6.38. STEERING CLUTCH DISASSEMBLY
• 6.39. STEERING CLUTCH ASSEMBLY
• 6.40. STEERING BRAKE VALVE DISASSEMBLY
• 6.41. STEERING BRAKE VALVE ASSEMBLY
• 6.42. FINAL DRIVE DISASSEMBLY
• 6.43. FINAL DRIVE ASSEMBLY
• 6.44. TRACK SHOE REMOVAL
• 6.45. TRACK SHOE INSTALLATION
• 6.46. TRACK FRAME REMOVAL
• 6.47. TRACK FRAME INSTALLATION
• 6.48. RECOIL SPRING REMOVAL
• 6.49. RECOIL SPRING INSTALLATION
• 6.50. RECOIL SPRING DISASSEMBLY
• 6.51. RECOIL SPRING ASSEMBLY
• 6.52. IDLER REMOVAL AND INSTALLATION
• 6.53. TRACK ROLLER REMOVAL AND INSTALLATION
• 6.54. CARRIER ROLLER REMOVAL AND INSTALLATION
• 6.55. RIGHT, CENTER GATE FRAME REMOVAL
• 6.56. RIGHT, CENTER GATE FRAME INSTALLATION
• 6.57. COUNTERWEIGHT FRAME REMOVAL
• 6.58. COUNTERWEIGHT FRAME INSTALLATION
• 6.59. BOOM, LEFT GATE FRAME REMOVAL AND INSTALLATION
• 6.60. WINCH DISMOUNTING
• 6.61. WINCH MOUNTING
• 6.62. WINCH CONTROL AND PPC VALVE DISMOUNTING AND MOUNTING
• 6.63. HIGH/LOW VALVE DISMOUNTING AND MOUNTING
• 6.64. WINCH DISASSEMBLY
• 6.64.1. WINCH
• 6.64.2. BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH.
• 6.64.3. BOOM BRAKE, HOOK BRAKE
• 6.64.4. PPC VALVE
• 6.64.5. CONTROL
• 6.64.6. HI, LO SELECTOR VALVE
• 6.64.7. FLOW DIVIDER VALVE
• 6.64.8. STRAINER ASSEMBLY
• 6.64.9. FILTER ASSEMBLY
• 6.65. WINCH ASSEMBLY
• 6.65.1. WINCH
• 6.65.2. BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH.
• 6.65.3. BOOM BRAKE, HOOK BRAKE
• 6.65.4. PPC VALVE ASSEMBLY
• 6.65.5. CONTROL
• 6.65.6. HI, LO SELECTOR VALVE
• 6.65.7. FLOW DIVIDER VALVE
• 6.65.8. STRAINER
• 6.65.9. FILTER
• 6.65.10. WINCH
• 6.66. WINCH PUMP DISMOUNTING AND MOUNTING
• 6.67. COUNTERWEIGHT PUMP REMOVAL AND INSTALLATION
• 6.68. COUNTERWEIGHT CYLINDER REMOVAL AND INSTALLATION
• 6.69. COUNTERWEIGHT CYLINDER DISASSEMBLY
• 6.70. COUNTERWEIGHT CYLINDER ASSEMBLY
• 6.71. COUNTERWEIGHT CONTROL VALVE REMOVAL AND INSTALLATION
• 6.72. COUNTERWEIGHT CONTROL VALVE DISASSEMBLY
• 6.73. COUNTERWEIGHT CONTROL VALVE ASSEMBLY
• 6.74. CAUTION WHEN ASSEMBLING SHEAVE BLOCK
• 6.75. CAB REMOVAL AND INSTALLATION
• 7. MAINTENANCE STANDARD
• 7.1. ENGINE MOUNT
• 7.3. TORQUE CONVERTER
• 7.4. TORQFLOW TRANSMISSION
• 7.5. TRANSMISSION CONTROL VALVE
• 7.6. TRANSMISSION LUBRICATION VALVE
• 7.7. TRANSMISSION PUMP
• 7.8. BEVEL GEAR SHAFT
• 7.9. STEERING CLUTCH
• 7.10. STEERING BRAKE
• 7.11. STEERING AND BRAKE CONTROL VALVE
• 7.12. STEERING MAIN RELIEF VALVE
• 7.13. COUNTERWEIGHT PUMP
• 7.14. HIGHLOW VALVE
• 7.15. PPC VALVE
• 7.16. FLOW DIVIDER VALVE
• 7.17. WINCH
• 7.18. WINCH CLUTCH
• 7.19. WINCH BRAKE
• 7.20. COUNTERWEIGHT CONTROL VALVE
• 7.21. COUNTERWEIGHT CYLINDER
• 7.22. SLOW RETURN VALVE
• 7.23. COUNTERWEIGHT
• 7.24. BOOM, HOOK AND SHEAVE