Komatsu D85ESS-2 Crawler Dozer Shop Manual SEBM003001

Description

• Model List:
  • D85ESS-2 Crawler Dozer

• 1. COVER
• 2. CONTENTS
• 3. GENERAL
• 3.1. GENERAL ASSEMBLY DRAWING
• 3.2. SPECIFICATIONS
• 3.3. WEIGHT TABLE
• 3.4. TABLE OF FUEL, COOLANT AND LUBRICANTS
• 4. STRUCTURE AND FUNCTION
• 4.1. RADIATOR, OIL COOLER
• 4.2. ENGINE CONTROL
• 4.3. POWER TRAIN SYSTEM
• 4.4. POWER TRAIN SKELETON
• 4.5. POWER TRAIN UNIT
• 4.6. POWER TRAIN HYDRAULIC PIPING DIAGRAM
• 4.7. POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
• 4.8. POWER TRAIN HYDRAULIC SYSTEM DIAGRAM
• 4.9. DAMPER, UNIVERSAL JOINT
• 4.10. TORQUE CONVERTER AND PTO
• 4.11. TRANSMISSION CONTROL
• 4.12. TRANSMISSION
• 4.13. TRANSMISSION CONTROL VALVE
• 4.14. MAIN RELIEF VALVE
• 4.15. LUBRICATION RELIEF VALVE
• 4.16. STEERING, BRAKE CONTROL
• 4.17. BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
• 4.18. STEERING CONTROL VALVE
• 4.19. REDUCING VALVE
• 4.20. SCAVENGING PUMP STARAINER
• 4.21. POWER TRAIN OIL STRAINER
• 4.22. POWER TRAIN OIL FILTER
• 4.23. WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
• 4.24. WORK EQUIPMENT CONTROL
• 4.25. WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
• 4.26. WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
• 4.27. HYDRAULIC TANK AND FILTER
• 4.28. MAIN CONTROL VALVE
• 4.29. OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT
• 4.30. PISTON VALVE
• 4.31. WORK EQUIPMENT
• 4.32. ELECTRICAL CIRCUIT DIAGRAM
• 4.33. ENGINE CONTROL
• 4.34. MACHINE MONITOR SYSTEM
• 4.35. SENSORS
• 5. TESTING AND ADJUSTING
• 5.1. STANDARD VALUE TABLE FOR ENGINE
• 5.2. STANDARD VALUE TABLE FOR CHASSIS
• 5.3. STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
• 5.4. TOOL LIST FOR TESTING AND ADJUSTING
• 5.5. ADJUSTING VALVE CLEARANCE
• 5.6. MEASURING COMPRESSION PRESSURE
• 5.7. MEASURING BLOWBY
• 5.8. ADJUSTING FUEL INJECTION TIMING
• 5.9. MEASURING EXHAUST COLOR
• 5.10. MEASURING BOOST PRESSURE
• 5.11. MEASURING EXHAUST TEMPERATURE
• 5.12. MEASURING ENGINE OIL PRESSURE
• 5.13. MEASURING ENGINE SPEED
• 5.14. TESTING FAN BELT TENSION
• 5.15. MEASURING SPEED AT TORQUE CONVERTER STALL
• 5.16. ADJUSTING FUEL CONTROL LINKAGE
• 5.17. ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE
• 5.18. ADJUSTING BRAKE PEDAL LINKAGE
• 5.19. ADJUSTING WORK EQUIPMENT CONTROL LINKAGE
• 5.20. MEASURING POWER TRAIN OIL PRESSURE
• 5.21. MEASURING AND ADJUSTING BLADE CONTROL OIL PRESSURE
• 5.22. BLEEDING AIR FROM HYDRAULIC CYLINDER
• 5.23. RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
• 5.24. PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE
• 5.25. PROCEDURE FOR TESTING SENSORS
• 5.26. TROUBLESHOOTING
• 5.26.1. POINTS TO REMEMBER WHEN TROUBLESHOOTING
• 5.26.2. SEQUENCE OF EVENTS IN TROUBLESHOOTING
• 5.26.3. POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
• 5.26.4. CHECK BEFORE TROUBLESHOOTING
• 5.26.5. METHOD OF USING TROUBLESHOOTING CHARTS
• 5.26.6. CONNECTOR POSITION DRAWING
• 5.26.7. CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
• 5.26.8. ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM
• 5.26.9. TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
• 5.26.10. TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)
• 5.26.11. TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
• 5.26.12. TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M 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. ENGINE OIL COOLER CORE
• 6.4.1. REMOVAL
• 6.4.2. INSTALLATION
• 6.5. FUEL INJECTION PUMP
• 6.6. ENGINE FRONT SEAL
• 6.6.1. REMOVAL
• 6.6.2. INSTALLATION
• 6.7. ENGINE REAR SEAL
• 6.8. HYDRAULIC OIL COOLER
• 6.9. POWER TRAIN UNIT
• 6.9.1. REMOVAL
• 6.9.2. INSTALLATION
• 6.9.3. SEPARATION
• 6.9.4. CONNECTION
• 6.10. TORQUE CONVERTER
• 6.11. TORQFLOW TRANSMISSION
• 6.12. TORQUE CONVERTER VALVE
• 6.12.1. REMOVAL
• 6.12.2. INSTALLATION
• 6.12.3. DISASSEMBLY
• 6.12.4. ASSEMBLY
• 6.13. TRANSMISSION CONTROL VALVE
• 6.13.1. REMOVAL
• 6.13.2. INSTALLATION
• 6.13.3. DISASSEMBLY
• 6.13.4. ASSEMBLY
• 6.14. STEERING CONTROL VALVE
• 6.15. SCAVENGING PUMP
• 6.15.1. REMOVAL
• 6.15.2. INSTALLATION
• 6.16. POWER TRAIN PUMP
• 6.16.1. CHECKING BEFORE REMOVAL
• 6.16.2. REMOVAL
• 6.16.3. INSTALLATION
• 6.16.4. OVERALL DISASSEMBLY
• 6.16.5. OVERALL ASSEMBLY
• 6.16.6. PRESSFITTING JIG DIMENSION TABLE FOR LINK PRESS
• 6.16.7. FIELD DISASSEMBLY OF ONE LINK
• 6.16.8. FIELD ASSEMBLY OF ONE LINK
• 6.17. EQUALIZER BAR SIDE BUSHING
• 6.18. WORK EQUIPMENT PUMP
• 6.18.1. REMOVAL
• 6.18.2. INSTALLATION
• 6.19. MAIN CONTROL VALVE
• 6.20. BLADE LIFT CYLINDER
• 7. MAINTENANCE STANDARD
• 7.1. ENGINE MOUNT
• 7.2. POWER TRAIN UNIT MOUNT
• 7.3. DAMPER, UNIVERSAL JOINT
• 7.4. TORQUE CONVERTER, PTO
• 7.5. TRANSMISSION
• 7.6. TRANSMISSION CONTROL VALVE
• 7.7. MAIN RELIEF VALVE
• 7.8. BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
• 7.9. STEERING CONTROL VALVE
• 7.10. POWER TRAIN, LUBRICATION PUMP
• 7.11. FINAL DRIVE
• 7.12. HULL FRAME
• 7.13. TRACK FRAME, RECOIL SPRING
• 7.14. MAIN CONTROL VALVE
• 7.15. WORK EQUIPMENT CYLINDER
• 7.16. WORK EQUIPMENT
• 7.17. CUTTING EDGE, END BIT
• 8. OTHERS
• 8.1. GENERAL
• 8.1.1. SPECIFICATION
• 8.1.2. POWER TRAIN SYSTEM
• 8.2. STRUCTURE AND FUNCTION
• 8.2.1. GENERAL VIEW
• 8.2.2. WINCH SECTION
• 8.2.3. HYDRAULIC SYSTEM
• 8.2.4. CONTROL OF WINCH
• 8.2.5. FAIRLEAD
• 8.3. TESTING AND ADJUSTING
• 8.3.1. STANDARD VALUE TABLE FOR TOWING WINCH
• 8.3.2. TOOL LIST FOR TESTING AND ADJUSTING
• 8.3.3. ADJUSTING TOWING WINCH CONTROL LEVER
• 8.3.4. MEASURING AND ADJUSTING TOWING WINCH OIL PRESSURE
• 8.3.5. TABLE OF FAILURE MODES AND CAUSES
• 8.4. DISASSEMBLY AND ASSEMBLY
• 8.4.1. METHOD OF USING MANUAL
• 8.4.2. PRECAUTIONS WHEN CARRYING OUT OPERATION
• 8.4.3. SPECIAL TOOL LIST
• 8.4.4. TOWING WINCH ASSEMBLY
• 8.4.5. TOWING WINCH PUMP ASSEMBLY
• 8.4.6. TOWING WINCH CONTROL VALVE ASSEMBLY
• 8.4.7. TOWING WINCH ASSEMBLY
• 8.4.8. ASSEMBLING INFORMATION
• 8.5. MAINTENANCE STANDARD
• 8.5.1. CLUTCH
• 8.5.2. BRAKE
• 8.5.3. VALVE
• 8.5.4. TOWING WINCH PUMP