Komatsu Bulldozer D85ESS-2A service & repair manual

Description Komatsu Bulldozer D85ESS-2A service & repair manual

Komatsu Bulldozer D85ESS-2A pdf workshop service repair manual

Serial numbers:
3001 and up

Technical data, specifications, maintenance, testing, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
SAFETY
SAFETY NOTICE

FOREWORD
GENERAL
HOW TO READ THE SHOP MANUAL
HOISTING INSTRUCTIONS
METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER
COATING MATERIALS
STANDARD TIGHTENING TORQUE
ELECTRIC WIRE CODE
CONVERSION TABLE
UNITS

GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
TABLE OF FUEL, COOLANT AND LUBRICANTS

STRUCTURE AND FUNCTION
RADIATOR, OIL COOLER
ENGINE CONTROL
POWER TRAIN SYSTEM
POWER TRAIN SKELETON
POWER TRAIN UNIT
POWER TRAIN HYDRAULIC PIPING DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM
DAMPER, UNIVERSAL JOINT
TORQUE CONVERTER AND PTO
TRANSMISSION CONTROL
TRANSMISSION
TRANSMISSION CONTROL VALVE
MAIN RELIEF VALVE
LUBRICATION RELIEF VALVE
STEERING, BRAKE CONTROL
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
STEERING CONTROL VALVE
STEERING BRAKE VALVE
REDUCING VALVE
SCAVENGING PUMP STRAINER
POWER TRAIN OIL STRAINER
POWER TRAIN OIL FILTER
FINAL DRIVE
MAIN FRAME
TRACK FRAME
RECOIL SPRING
SUSPENSION
WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM
PPC CONTROL PIPING DIAGRAM
WORK EQUIPMENT CONTROL
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (ANGLEDOZER)
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (ANGLEDOZER)
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM (STRAIGHT TILTDOZER)
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM (STRAIGHT TILTDOZER)
HYDRAULIC TANK AND FILTER
PPC VALVE
PPC CHARGE VALVE
PPC LOCK VALVE
MAIN CONTROL VALVE
OPERATION OF MAIN CONTROL VALVE
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT
SUCTION VALVE
PISTON VALVE
WORK EQUIPMENT
ELECTRICAL CIRCUIT DIAGRAM
ENGINE CONTROL
MACHINE MONITOR SYSTEM (GAUGE TYPE PANEL)
MACHINE MONITOR SYSTEM (MONITOR TYPE PANEL)

TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE
STANDARD VALUE TABLE FOR CHASSIS
STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM
TOOL LIST FOR TESTING AND ADJUSTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
MEASURING BLOWBY
ADJUSTING FUEL INJECTION TIMING
MEASURING EXHAUST COLOR
MEASURING BOOST PRESSURE
MEASURING EXHAUST TEMPERATURE
MEASURING ENGINE OIL PRESSURE
MEASURING ENGINE SPEED
TESTING FAN BELT TENSION
MEASURING SPEED AT TORQUE CONVERTER STALL
ADJUSTING FUEL CONTROL LINKAGE
ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE
ADJUSTING BRAKE PEDAL LINKAGE
ADJUSTING WORK EQUIPMENT CONTROL LINKAGE
ADJUSTING STRAIGHT TILTDOZER
ADJUSTING PPC VALVE
MEASURING POWER TRAIN OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE
MEASURING OUTPUT PRESSURE OF PPC VALVE
MEASURING LEAKAGE INSIDE CYLINDER
BLEEDING AIR FROM HYDRAULIC CYLINDER
RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT
PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE
PROCEDURE FOR TESTING SENSORS
TESTING AND ADJUSTING OF VIBRATION STOPPER, OPEN OPEN/CLOSE LOCK OF OPERATOR’S CAB DOOR
ADJUSTMENT PROCEDURE FOR ENGINE COOLANT TEMPERATURE GAUGE AND POWER TRAIN OIL TEMPERATURE GAUGE

TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINT TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECK BEFORE TROUBLESHOOTING
METHOD OF USING MATRIX TROUBLESHOOTING CHARTS
METHOD OF USING TROUBLESHOOTING CHARTS
TYPE OF CONNECTOR AND POSITION OF INSTALLATION
CONNECTOR POSITION DRAWING
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS
ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) GAUGE TYPE PANEL
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE) MONITOR TYPE PANEL

DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SPECIAL TOOL SKETCH
STARTING MOTOR
ALTERNATOR
ENGINE OIL COOLER CORE
FUEL INJECTION PUMP
WATER PUMP
TURBOCHAGER
NOZZLE NOLDER
THERMOSTAT
CYLINDER HEAD
ENGINE FRONT SEAL
ENGINE REAR SEAL
AIR COMPRESSOR
AIR CONDENSER
FUEL TANK
RADIAOR
HYDRAULIC OIL COOLER
ENGINE (CAB SPECIFICATION)
ENGINE (CANOPY SPESIFICATION)
DAMPER
POWER TRAIN UNIT
TORQUE CONVERTER
PTO
TORQFLOW TRANSMISSION
STEERING CASE
TORQUE CONVERTER VALVE
TRANSMISSION CONTROL VALVE
STEERING CONTROL VALVE
REDUCING VALVE
SCAVENGING PUMP
POWER TRAIN PUMP
FINAL DRIVE
TRACK FRAME
RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
PIVOT SHAFT
EQUALIZER BAR
EQUALIZER BAR SIDE BUSHING
SEGMENT TEETH
WORK EQUIPMENT PUMP
PPC PUMP
MAIN CONTROL VALVE
RIPPER VALVE
MAIN RELIEF VALVE
PPC VALVE
PPC CHARGE RELIEF VALVE
SUCTION VALVE
BLADE LIFT CYLINDER (ANGLEDOZER)
BLADE LIFT CYLINDER (STRAIGHT TILT DOZER)
BLADE TILT CYLINDER
HYDRAULIC SYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER)
BLADE (ANGLEDOZER)
BLADE (STRAIGHT TILT DOZER)
ROPS GUARD
CAB
CANOPY
DASHBOARD (GAUGETYPE PANEL)
DASHBOARD (MONITOR TYPE PANEL)
PANEL (GAUGETYPE PANEL)
PANEL (MONITOR TYPE PANEL)
FLOOR FRAME (CANOPY SPECIFICATION)
FLOOR FRAME (CAB SPECIFICATION)

MAINTENANCE STANDARD
ENGINE MOUNT
POWER TRAIN UNIT MOUNT
DAMPER, UNIVERSAL JOINT
TORQUE CONVERTER, PTO
TRANSMISSION
TRANSMISSION CONTROL VALVE
MAIN RELIEF VALVE
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
STEERING CONTROL VALVE
STEERING BRAKE VALVE
POWER TRAIN, LUBRICATION PUMP
PPC PUMP
PPC VALVE
PPC CHARGE VALVE
FINAL DRIVE
HULL FRAME
TRACK FRAME, RECOIL SPRING
IDLER
TRACK ROLLER
CARRIER ROLLER
TRACK SHOE
SUSPENSION
HYDRAULIC PUMP
MAIN CONTROL VALVE
WORK EQUIPMENT CYLINDER
WORK EQUIPMENT
CUTTING EDGE, END BIT
RIPPER

OTHERS
1. GENERAL
1-1 SPECIFICATION
1-2 POWER TRAIN SYSTEM
2. STRUCTURE AND FUNCTION
2-1 GENERAL VIEW
2-2 WINCH SECTION
2-3 HYDRAULIC SYSTEM
2-4 CONTROL OF WINCH
2-5 FAIRLEAD
3. TESTING AND ADJUSTING
3-1 STANDARD VALUE TABLE FOR TOWING WINCH
3-2 TOOL LIST FOR TESTING AND ADJUSTING
3-3 ADJUSTING WINCH CONTROL LEVER
3-4 MEASURING AND ADJUSTING WINCH HYDRAULIC PRESSURE
3-5 TABLE OF FAILURE MODES AND CAUSES
4. DISASSEMBLY AND ASSEMBLY
PRECAUTIONS WHEN CARRYING OUT OPERATION
4-1 SPECIAL TOOL LIST
4-2 TOWING WINCH ASSEMBLY
4-3 TOWING WINCH PUMP ASSEMBLY
4-4 TOWING WINCH CONTROL VALVE ASSEMBLY
4-5 TOWING WINCH ASSEMBLY
4-6 ASSEMBLING INFORMATION
5. MAINTENANCE STANDARD
5-1 CLUTCH
5-2 BRAKE
5-3 VALVE
5-4 TOWING WINCH PUMP

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