Komatsu Bulldozer D85ESS-3 service & repair manual

Description Komatsu Bulldozer D85ESS-3 service & repair manual

Komatsu Bulldozer D85ESS-3 pdf workshop service repair manual

Serial numbers:
10001 and up

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

MANUAL CONTENT:
Index and foreword
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic components
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out work
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
List of Abbreviation
Conversion table

Specification
Specification drawing
Weight table
Table of fuel, coolant, and lubricants

Structure and function
Engine and cooling system
Damper
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Overall drawing of power train unit
Hydraulic piping drawing of power train
Transmission, steering, and brake control
Universal joint
Torque converter and PTO
Transmission
Transmission control valve
Main relief valve
Lubrication relief valve
Bevel gear shaft, steering clutch, steering brake
Steering brake valve
Reducing valve
Scavenging pump strainer
Power train oil strainer
Final drive
Undercarriage and frame
Main frame
Suspension
Track frame
Recoil spring
Hydraulic system
Hydraulic component layout
Hydraulic tank
Work equipment pump
Steering lubrication pump and power train pump
Scavenging pump
Control valve
Steering PPC valve
Blade PPC valve
Ripper PPC valve
Quick drop valve
PPC lock valve
Hydraulic oil cooler bypass valve
PPC circuit accumulator
Work equipment
Angle dozer
Straight tilt dozer
Ripper
Piston valve
Floor frame and its attachments
Floor mount
Electrical system
Engine control
Engine control system
Cooling system control system
Machine monitor system
KOMTRAX system
KOMTRAX terminal
System component parts
Power train controller
Sensors

Standard value table
Standard value table for engine
Standard value table for machine

Testing and adjusting
Related information on testing and adjusting
Tools for testing, adjusting, and troubleshooting
Engine and cooling system
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust gas temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blowby pressure
Testing engine oil pressure
Handling equipment of fuel system devices
Releasing remaining pressure from fuel system
Testing fuel pressure
Testing fuel return rate and leakage
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling cylinder cutout mode operation
Handling no-injection cranking operation
Replacing alternator belt
Adjusting fuel control linkage
Adjusting decelerator pedal
Handling engine controller high voltage circuit
Power train
Measuring power train oil pressure
Procedure for simple test of steering brake performance
Adjusting brake pedal linkage
Adjusting steering and directional lever, gear shift lever, parking brake lever linkage
Hydraulic system
Testing and adjusting work equipment hydraulic pressure
Testing and adjusting control circuit pressure
Measuring output pressure of PPC valve
Testing and adjusting play of work equipment PPC valve
Testing internal oil leakage of work equipment cylinder
Bleeding air from work equipment cylinders
Releasing remaining pressure in work equipment cylinder
Isolating parts that cause hydraulic drift of blade and ripper
Testing fan speed
Testing fan circuit oil pressure
Bleeding air from fan pump
Work equipment
Adjusting straight tilt dozer
Adjusting work equipment lock lever
Procedure for testing sensors
Electrical system
Special functions of machine monitor
How to start operation of KOMTRAX terminal
Handling voltage circuit of engine controller
Adjustment method when controller is replaced
Preparation for troubleshooting of electrical system
Testing diodes
Pm Clinic
Pm Clinic service

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Checks before troubleshooting
Preparation for troubleshooting of the electrical system
Classification and procedures of troubleshooting
Symptoms and troubleshooting Nos
Information described in the failure code list
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Connector list and layout
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Fuse location table
Troubleshooting by failure code (code display)
Troubleshooting for the electrical system (E-mode)
Troubleshooting for hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
Related information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of power train oil cooler assembly
Removal and installation of cooling fan drive assembly
Removal and installation of cooling fan motor assembly
Removal and installation of engine assembly
Disassembly and assembly of damper assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of engine hood assembly
Removal and installation of fuel tank assembly
Power train
Removal and installation of power train unit assembly
Separation and connection of power train unit
Disassembly and assembly of torque converter assembly
Disassembly and assembly of PTO assembly
Disassembly and assembly of TORQFLOW transmission assembly
Disassembly and assembly of steering case assembly
Removal and installation of torque converter valve assembly
Disassembly and assembly of torque converter valve assembly
Removal and installation of transmission control valve assembly
Disassembly and assembly of transmission control valve assembly
Removal and installation of brake valve assembly
Disassembly and assembly of brake valve assembly
Removal and installation of reducing valve assembly
Disassembly and assembly of reducing valve assembly
Removal and installation of scavenging pump assembly
Removal and installation of power train pump assembly
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Removal and installation of track frame assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of roller assembly
Disassembly and assembly of carrier roller assembly
Removal and installation of track shoe assembly
Overall disassembly and assembly of track shoe
Press-fitting jig dimension table for link press
Field disassembly and assembly of one link
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Removal and installation of equalizer bar side bushing
Removal and installation of segment teeth
Hydraulic system
Removal and installation of work equipment pump assembly
Removal and installation of cooling fan pump assembly
Removal and installation of main control valve assembly
Disassembly and assembly of main control valve assembly
Disassembly and assembly of ripper valve assembly
Removal and installation of main relief valve
Removal and installation of PPC valve assembly
Disassembly and assembly of PPC valve assembly
Removal and installation of suction valve assembly
Removal and installation of blade lift cylinder assembly
Removal and installation of blade tilt cylinder assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Disassembly and assembly of blade assembly
Floor frame and its attachments
Removal and installation of dashboard assembly
Removal and installation of floor frame assembly
Electrical system
Removal and installation of monitor panel assembly
Removal and installation of engine controller assembly
Removal and installation of power train controller assembly
Removal and installation of KOMTRAX terminal assembly

Maintenance standard
Engine and cooling system
Engine mount
Damper
Cooling system
Cooling fan pump
Cooling fan motor
Power train
Power train mount
Universal joint
Torque converter and PTO
Transmission
Transmission control valve
Main relief valve
Bevel gear shaft, steering clutch, and steering brake
Steering brake valve
Final drive
Sprocket
Undercarriage and frame
Main frame
Suspension
Track frame and recoil spring
Idler
Track roller
Carrier roller
Track shoe
Hydraulic system
Work equipment pump
Power train and lubrication pump
Scavenging pump
Control valve
Steering PPC valve
Blade PPC valve
Ripper PPC valve
Quick drop valve
Work equipment
Cutting edge and end bit
Ripper
Lift cylinder
Tilt cylinder
Ripper cylinder
Floor frame and its attachments
Floor mount

Diagrams and drawings
Hydraulic diagrams and drawings
Symbols used in hydraulic circuit diagrams
Power train hydraulic circuit diagram
Hydraulic circuit diagram
Electrical diagrams and drawings
Symbols used in electric circuit diagrams
Electrical circuit diagram

Engine SAA6D114E-3 workshop service manual