Komatsu Bulldozer D85EX-15R D85PX-15R service & repair manual

Description Komatsu Bulldozer D85EX-15R D85PX-15R service & repair manual

Komatsu Bulldozer D85EX-15R, D85PX-15R pdf workshop service repair manual

Serial numbers:
20001 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
Composition of shop manual
Table of contents
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification dimensions
Specifications
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Engine mount
Cooling system
Cooling fan pump
Cooling fan motor
Power train
HSS system
General view of power train unit
Power train hydraulic piping drawing
Transmission control
Steering and brake control
Damper and universal joint
Torque converter and PTO
Transmission
Transmission clutch ECMV
Main relief valve and torque converter relief valve
Lubrication relief valve
Bevel gear shaft, HSS and brake
Brake valve
Final drive
Undercarriage and frame
Main frame
Suspension
Track frame
Idler cushion
Idler
Track roller
Carrier roller
Sprocket
Track shoe
Hydraulic system
Work equipment hydraulic piping diagram
PPC control piping diagram
Work equipment control
Hydraulic tank and filter
Scavenging pump
Power train and steering lubrication pump
HSS pump
HSS motor
Control valve
Self pressure reducing valve
Oil cooler bypass valve
PPC valve
Electric lever (steering)
Quick drop valve
PPC lock valve
Accumulator
Work equipment
Cylinder stay
Blade
Cutting edge and end bit
Ripper
Hydraulic cylinder
Piston valve
Cab and its attachments
Cab mount
Cab
Air conditioner
Electrical system
Monitor system
Monitor panel
Engine control
Engine control system
System components
CRI engine control system
Palm command control system
KOMTRAX system
Sensor

Standard value table
Standard service value table
Standard service value table for engine
Standard service value table for chassis

Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Measuring engine speed
Measuring intake air pressure (boost pressure)
Measuring exhaust temperature
Measuring exhaust gas color
Adjusting valve clearance
Measuring compression pressure
Measuring blow-by pressure
Measuring engine oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Testing fuel return and leak amount
Bleeding air from fuel circuit
Testing and adjusting alternator belt tension
Testing and adjusting air conditioner compressor belt tension
Adjusting fuel control dial and decelerator pedal
Measuring power train oil pressure
Adjusting transmission speed sensor
Simple method to test brake performance
Adjusting brake pedal
Adjusting parking brake lever
Emergency escape method when power train has trouble
Adjusting clearance of idler
Inspecting wear of sprocket
Testing and adjusting track shoe tension
Testing and adjusting work equipment and HSS oil pressure
Testing control circuit basic pressure
Measuring PPC valve output pressure
Adjusting work equipment PPC valve play
Checking parts which caused hydraulic drift of blade and ripper
Measuring internal leakage of work equipment cylinder
Bleeding air from work equipment cylinder
Releasing residual pressure in work equipment cylinder
Adjusting work equipment lock lever
Measuring fan motor speed
Measuring fan pump circuit pressure
Bleeding air from fan pump
Adjusting blade
Testing and adjusting operator cab
Special functions of monitor panel (EMMS)
Adjustment method when controller has been replaced
Preparation work for troubleshooting for electrical system
Inspection procedure of diode
Handing of optional devices
Pm Clinic service
How to start operation of KOMTRAX terminal
Lamp display of KOMTRAX terminal

Troubleshooting
Failure code table and fuse locations
Failure code table
Before troubleshooting by failure codes
General information on troubleshooting
Points to remember when troubleshooting
How to proceed troubleshooting
Checks before troubleshooting
Classification and procedures of troubleshooting
Contents of troubleshooting table
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting by failure code (Display of code)
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tools list
Sketch of special tool
Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of cylinder head assembly
Removal and installation of fuel injector assembly
Removal and installation of engine front seal
Removal and installation of engine rear seal
Removal and installation of engine oil pan
Removal and installation of engine assembly
Removal and installation of radiator assembly
Removal and installation of fan drive assembly
Removal and installation of fan motor assembly
Removal and installation of fuel tank assembly
Removal and installation of damper assembly
Disassembly and assembly of damper assembly
Removal and installation of engine hood assembly
Power train
Removal and installation of power train unit assembly
Disconnection and connection of power train unit assembly
Disassembly and assembly of PTO assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of TORQFLOW transmission assembly
Disassembly and assembly of HSS 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 idler assembly
Disassembly and assembly of idler assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Expansion and installation of track shoe assembly
Whole disassembly and whole assembly of track shoe assembly
Field disassembly and assembly of one link
Disassembly and assembly of master link
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Disassembly and assembly of equalizer bar assembly
Open and close center under guard
Remove and install center under guard assembly
Hydraulic system
Removal and installation of work equipment control valve assembly
Disassembly and assembly of work equipment control valve assembly
Removal and installation of HSS and work equipment pump assembly
Removal and installation of power train and lubricating oil pump assembly
Removal and installation of fan pump assembly
Removal and installation of scavenging pump assembly
Removal and installation of HSS motor assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Removal and installation of blade lift cylinder assembly
Disassembly and assembly of ripper assembly
Disassembly and assembly of fixed multi-shank ripper assembly
Disassembly and assembly of variable multi-shank ripper assembly
Cab and its attachments
Removal and installation of ROPS guard assembly
Removal and installation of operator’s cab assembly
Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of floor frame assembly
Electrical system
Removal and installation of engine controller
Removal and installation of steering and transmission controller
Removal and installation of KOMTRAX terminal

Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram
Cab electrical circuit diagram
Air conditioner electrical circuit diagram
Connector list and stereogram

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