Komatsu D85E-SS-2A Bulldozer (3001 and up) Shop Manual - SEBM002904

This complete service repair workshop manual PDF download for the Komatsu D85E-SS-2 Crawler Tractor (SN: 3001 and up) has easy to read text sections with top quality diagrams, pictures and illustrations. The step by step instructions show you how to fault find or complete any repair or overhaul, correctly and efficiently, saving time and avoiding costly mistakes. All specifications and tolerances are listed. Functions of components and systems are also explained.


APPLICABLE MODELS :

Komatsu D85E-SS-2A
Serial Numbers : 3001 and up
Engine: S60125-1 and S60125-2


TABLE OF CONTENTS :

- GENERAL
- STRUCTURE AND FUNCTION
- MAINTENANCE STANDARD
- TESTING AND ADJUSTING
- DISASSEMBLY AND ASSEMBLY
- OTHERS


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM002904
Total Pages : 906


D85E-SS-2A mount the S60125-1 and S60125-2 engine.
For details of the engine, see the 60125 Series and 125-2 Series Engine Shop Manual.
This shop manual combines DWT065-1A towing winch in one volume.

This service repair workshop manual PDF download has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

This service repair workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same Repair Service manual your local dealer will use when doing a repair.

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TABLE OF CONTENTS :

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

10 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
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM
WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM
HYDRAULIC TANK AND FILTER
PPC VALVE
PPC CHARGE VAVLE
PPC LOCK VAVLE
MAIN CONTROL VALVE
OPERATION OF MAIN CONTROL VALVE
OPERATION OF WORK EQUIPMENT CONTROL CIRCUIT
SUCTION VAVLE
PISTON VALVE
WORK EQUIPMENT
ELECTRICAL CIRCUIT DIAGRAM
ENGINE CONTROL
MACHINE MONITOR SYSTEM (GAUGE TYPE PANEL)
MACHINE MONITOR SYSTEM (MONITOR TYPE PANEL)

20 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 VAVLE
MEASURING POWER TRAIN OIL PRESSURE
TESTING AND ADJUSTING WORK EQUIPNENT HYDRAULIC PRESSURE
TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE
MEASURING OUTPUT PRESSURE OF PPC VAVLE
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
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
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)
S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)
S-2 ENGINE DOES NOT START
① ENGINE DOES NOT TURN
② ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)
③ EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)
S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR)
S-4 ENGINE STOPS DURING OPERATIONS
S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT (NO POWER)
S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)
S-9 OIL BECOMES CONTAMINATED QUICKLY
S-10 FUEL CONSUMPTION IS EXCESSIVE
S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN
S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES
S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)
S-15 ABNORMAL NOISE IS MADE
S-16 VIBRATION IS EXCESSIVE
TROUBLESHOOTING OF HYDRAULIC MECHANICAL SYSTEM (H MODE)
TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC,MECHANICAL SYSTEM)
H-1 BRAKES DOES NOT WORK
H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN S STRAIGHT LINE)
H-3 OVERRUNS WHEN TURNING
H-4 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING AND DIRECTIONAL LEVER IS OPERATED)
H-5 EXCESSIVE TIME LAG
H-6 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)
H-7 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)
H-8 MACHINE DOES NOT MOVE IN ANY SPEED RANGE
H-9 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH
H-10 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW
H-11 ABNORMAL NOISE IS GENERATED FROM AROUND HYDRAULIC PUMP
H-12 SPEED OF ALL WORK EQUIPMENT IS SLOW
H-13 NO WORK EQUIPMENT MOVES
H-14 ALL WORK EQUIPMENT LACKS POWER
H-15 BLADE LIFTING SPEED IS SLOW OR LACKS POWER
H-16 BLADE TILT SPEED IS SLOW OR LACKS POWER
H-17 HYDRAULIC DRIFT OF BLADE LIFT IS EXCESSIVE
H-18 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)
TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)
E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO ON
E-2 LAMPS DO NOT LIGHT UP
a) FRONT LAMPS
b) REAR LAMPS
E-3 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO
E-4 WIPER DOES NOT WORK
E-5 NO WASHER FLUID IS SPRAYED OUT
E-6 AIR CONDITIONER HAS NO EFFECT
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
M-1 ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE
M-2 ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE
TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)
TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)
M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON
M-2 WHEN STARTING SWITCH IS TURNED ON,ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT
M-3 PREHEATING DISLAY IS ABNORMAL
a) PREHEATING MONITIOR DOES NOT LIGHT UP
b) PREHEATING MONITIOR DOES NOT GO OUT
M-4 CAUTION ITEMS LIGHT UP OR FLASH
a) (CHARGE)LIGHTS UP OR FLASHES
b) WHEN STARTING SWITCH IS AT ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES
c) (COOLANT TEMPERATURE) FLASHES
d) (POWER TRAIN OIL TEMPERATURE) FLASHES
M-5 BUZZER IS ABNORMAL
a) CAUTION ITEM FLASHES BUT BUZZER DOSE NOT SOUND
b) MONITOR DISPLAY IS NORMAL,BUT BUZZER SOUNDS
M-6 WARNING LAMP IS ABNORMAL
a) CAUTION ITEM FLASHING BUT LAMP DOES NOT FLASH
b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES
M-7 GAUGE IS ABNORMAL
a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE
b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE
c) ABNORMALITY IN FUEL LEVEL GAUGE
M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED
M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)

30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
SPECIAL TOOL SKETCH
STARTING MOTOR
REMOVAL
INSTALLATION
ALTERNATOR
REMOVAL
INSTALLATION
ALTERATOR
REMOVAL
INSYALLATION
ENGINE OIL COOLER CORE
REMOVAL
INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
WATER PUMP
REMOVAL
INSTALLATION
TURBOCHARGER
REMOVAL
INSTALLATION
NOZZLE HOLDER
REMOVAL
INSTALLATION
THERMOSTAT
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
ENGINE FRONT SEAL
REMOVAL
INSTALLATION
ENGINE REAR SEAL
REMOVAL
INSTALLATION
AIR COMPRESSOR
REMOVAL
INSTALLATION
AIR CONDENSER
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
FUEL TANK
REMOVAL
INSTALLATION
RADIATOR
REMOVAL
INSTALLATION
HYDRAULIC COOLER
REMOVAL
INSTALLATION
ENGINE (CAB SPECIFICATION)
REMOVAL
INSTALLATION
ENGINE (CANOPY SPECIFICATION)
REMOVAL
INSTALLATION
DAMPER
REMOVAL
INSTALLATION
POWER TRAIN UNIT
REMOVAL
INSTALLATION
SEPARATION
CONNECTION
TORQUE CONVERTER
DISASSEMBLY
ASSEMBLY
PTO
DISASSEMBLY
ASSEMBLY
TORQFLOW TRANSMISSION
DISASSEMBLY
ASSEMBLY
STEERING CASE
DISASSEMBLY
ASSEMBLY
TORQUE CONVERTER VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
REDUCING VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SCAVENGING PUMP
REMOVAL
INSTALLATION
POWER TARIN PUMP
REMOVAL
INSTALLATION
FINAL DRIVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK FRAME
REMOVAL
INSTALLATION
RECOIL SPRING
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
IDLER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK ROLLER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
CARRIER ROLLER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRACK SHOE
REMOVAL
INSTALLATION
OVERALL DISASSEMBLY
OVERALL ASSEMBLY
PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS
FIELD DISASSEMBLY OF ONE LINK
FIELD ASSEMBLY OF ONE LINK
PIVOT SHAFT
REMOVAL
INSTALLATION
EQUALIZER BAR
REMOVAL
INSTALLATION
EQUALIZER BAR SIDE BUSHING
REMOVAL
INSTALLATION
SEGMENT TEETH
REMOVAL
INSTALLATION
WORK EQUIPMENT PUMP
REMOVAL
INSTALLATION
PPC PUMP
REMOVAL
INSTALLATION
MAIN CONTROL VALVE
RENOVAL
INSTALLATION
MAIN CONTROL VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
RIPPER VALVE
DISASSEMBLY
ASSEMBLY
MAIN RELIEF VALVE
REMOVAL
INSTALLATION
PPC VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
PPC CHARGE RELIEF VALVE
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
SUCTION VALVE
REMOVAL
INSTALLATION
BLADE LIFT CYLINDER (ANGLEDOZER)
REMOVAL
INSTALLATION
BLADE LIFT CYLINDER (STRAIGHT TILT DOZER)
REMOVAL
INSTALLATION
BLADE TILT CYLINDER
REMOVAL
INSTALLATION
HYDRAULIC CYLINDER
DISASEMBLY
ASSEMBLY
BLADE (ANGLEDOZER)
REMOVAL
INSTALLATION
BLADE (STRAIGHT TILT DOZER)
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
ROPS GUARD
REMOVAL
INSTALLATION
CAB
REMOVAL
INSTALLATION
CANOPY
REMOVAL
INSTALLATION
DASHBOARD (GAUGE TYPE PANEL)
REMOVAL
INSTALLATION
DASHBOARD (MONITOR TYPE PANEL)
REMOVAL
INSTALLATION
PANEL (GAUGE TYPE PANEL)
REMOVAL
INSTALLATION
PANEL (MONITOR TYPE PANEL)
REMOVAL
INSTALLATION
FLOOR FRAME (CANOY SPECIFICATION)
REMOVAL
INSTALLATION
FLOOR FRAME (CAB SPECIFICATION)
REMOVAL
INSTALLATION

40 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

90 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
2-3-1 PIPING
2-3-2 HYDRAULIC CIRCUIT DIAGRAM
2-3-3 GENERAL VIEW OF CONTROL VALVE AND FUNCTION
2-3-4 CLUTCH STRUCTURE AND FUNCTION (INCL. LUBRICATION VALVE)
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 TOWING WINCH CONTROL LEVER
3-4 MEASURING AND ADJUSTING TOWING WINCH OIL PRESSURE
3-5 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEMS)
H-1 TOWING WINCH DOES NOT TURN
H-2 TOWING WINCH BRAKE DOES NOT WORK
4. DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
4-1 SPECIAL TOOL LIST
4-2 TOWING WINCH ASSEMBLY
REMOVAL
INSTALLATION
4-3 TOWING WINCH PUMP ASSEMBLY
REMOVAL
INSTALLATION
4-4 TOWING WINCH CONTROL VALVE ASSEMBLY
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
4-5 TOWING WINCH ASSEMBLY
DISASSEMBLY
ASSEMBLY
4-6 ASSEMBLING INFORMATION
4-6-1 BEARING CLEARANCE AND GEAR BACKLASH
5. MAINTENANCE STANDARD
5-1 CLUTCH
5-2 BRAKE
5-3 VALVE
5-4 TOWING WINCH PUMP
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