Komatsu D85C-21 PIPELAYER Shop Manual SEN04766-00 – PDF DOWNLOAD

Komatsu D85C-21 PIPELAYER Shop Manual SEN04766-00 – PDF DOWNLOAD

FILE DETAILS:

Komatsu D85C-21 PIPELAYER Shop Manual SEN04766-00 – PDF DOWNLOAD

Language : English
Pages : 554
Downloadable : Yes
File Type : PDF
Size: 14.1 MB

IMAGES PREVIEW OF THE MANUAL:

DESCRIPTION:

Komatsu D85C-21 PIPELAYER Shop Manual SEN04766-00 – PDF DOWNLOAD

MACHINE MODEL SERIAL NUMBER
D85C-21 36551 and up

GENERAL PRECAUTIONS:

Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.1 .Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2.When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.

•  Always wear safety glasses when hitting parts with a hammer.
•  Always wear safety glasses when grinding parts with a grinder, etc.

3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.4.When carrying out any operation with two or more workers, always agree on the op- erating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.5. Keep all tools in good condition and learn the correct way to use them.
6. Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.PREPARATIONS FOR WORK:
7. Before adding or making any repairs, park the machine on hard, level ground, and block the wheels to
prevent the machine from moving.
8. Before starting work, lower outrigger, bucket or any other work equipment to the ground. If this is not possible,
use blocks to prevent the work equipment from falling down. In addition, be sure to lock all the control levers and hang warning sign on them.
9. When disassembling or assembling, support the machine with blocks, jacks or stands before starting
work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine.Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.

TABLE OF CONTENTS:

Komatsu D85C-21 PIPELAYER Shop Manual SEN04766-00 – PDF DOWNLOAD

COVER……………………………………………………………………………………………. 1
CONTENTS…………………………………………………………………………………………. 2
01 GENERAL……………………………………………………………………………………….. 0
GENERAL ASSEMBLY DRAWING……………………………………………………………………….. 22
SPECIFICATIONS………………………………………………………………………………… 24
WEIGHT TABLE………………………………………………………………………………….. 30
TABLE OF OIL AND COOLANT QUANTITIES……………………………………………………………… 33
10 STRUCTURE AND FUNCTION………………………………………………………………………….. 0
RADIATOR SHUTTER………………………………………………………………………………. 38
POWER TRAIN…………………………………………………………………………………… 40
POWER TRAIN HYDRAULIC PIPING DIAGRAM…………………………………………………………….. 42
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM…………………………………………………………….. 44
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM……………………………………………………………. 45
PTO………………………………………………………………………………………….. 46
TORQUE CONVERTER………………………………………………………………………………. 48
TRANSMISSION CONTROL…………………………………………………………………………… 52
TORQFLOW TRANSMISSION………………………………………………………………………….. 54
TRANSMISSION CONTROL VALVE……………………………………………………………………… 60
TRANSMISSION LUBRICATION VALVE………………………………………………………………….. 65
STEERING, BRAKE CONTROL………………………………………………………………………… 66
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE…………………………………………………. 67
STEERING MAIN LELIEF VALVE……………………………………………………………………… 69
STEERING AND BRAKE CONTROL VALVE………………………………………………………………… 70
STEERING BRAKE………………………………………………………………………………… 74
TRANSMISSION AND STEERING OIL STRAINER…………………………………………………………… 78
TRANSMISSION AND STEERING OIL FILTER…………………………………………………………….. 79
FINAL DRIVE…………………………………………………………………………………… 80
TRACK GROUP…………………………………………………………………………………… 82
SUSPENSION……………………………………………………………………………………. 83
GATE FRAME……………………………………………………………………………………. 84
WINCH CONTROL…………………………………………………………………………………. 86
HYDRAULIC CIRCUIT DIAGRAM FOR WINCH……………………………………………………………… 89
WINCH………………………………………………………………………………………… 90
POWER TRAIN OF WINCH…………………………………………………………………………… 98
HIGH-LOW VALVE…………………………………………………………………………………104
PPC VALVE……………………………………………………………………………………..105
FLOW DIVIDER VALVE……………………………………………………………………………..107
WINCH OIL FILTER……………………………………………………………………………….110
WINCH OIL STRAINER……………………………………………………………………………..110
COUNTERWEIGHT HYDRAULIC TANK…………………………………………………………………….111
COUNTERWEIGHT PIPING……………………………………………………………………………112
COUNTERWEIGHT CONTROL…………………………………………………………………………..113
HYDRAULIC CIRCUIT SCHEMATICS FOR COUNTERWEIGHT…………………………………………………….114
HYDRAULIC CIRCUIT DIAGRAM FOR COUNTERWEIGHT……………………………………………………….115
COUNTERWEIGHT………………………………………………………………………………….116
COUNTERWEIGHT CONTROL VALVE……………………………………………………………………..118
BOOM………………………………………………………………………………………….119
SAFETY DEVICE………………………………………………………………………………….120
CAB…………………………………………………………………………………………..125
HEATER………………………………………………………………………………………..127
ACTUAL ELECTRICAL WIRING DIAGRAM…………………………………………………………………128
ELECTRICAL CIRCUIT DIAGRAM………………………………………………………………………131
20 TESTING AND ADJUSTING…………………………………………………………………………… 0
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS……………………………………………………..138
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…………………………………………………….141
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING………………………………………………….145
ADJUSTING VALVE CLEARANCE……………………………………………………………………….146
MEASURING COMPRESSION PRESSURE…………………………………………………………………..147
TESTING AND ADJUSTING FUEL INJECTION TIMING……………………………………………………….148
MEASURING ENGINE OIL PRESSURE……………………………………………………………………150
MEASURING EXHAUST COLOR…………………………………………………………………………151
MEASURING EXHAUST TEMPERATURE……………………………………………………………………152
TESTING AND ADJUSTING ALTERNATOR BELT TENSION……………………………………………………..153
MEASURING BLOW-BY PRESSURE………………………………………………………………………154
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)…………………………………………………….155
MEASURING ENGINE SPEED………………………………………………………………………….156
MEASURING TORQUE CONVERTER STALL SPEED……………………………………………………………157
BLEEDING AIR…………………………………………………………………………………..158
ADJUSTING STROKE, LINKAGE……………………………………………………………………….159
1. ADJUSTING FUEL CONTROL LINKAGE…………………………………………………………….159
2. ADJUSTING GEAR SHIFT LEVER LINKAGE…………………………………………………………161
3. ADJUSTING STEERING LEVER LINKAGE…………………………………………………………..163
4. ADJUSTING TRAVEL OF BRAKE PEDAL……………………………………………………………164
5. ADJUSTING BRAKE PEDAL LINKAGE……………………………………………………………..165
6. ADJUSTING COUNTERWEIGHT CONTROL LINKAGE…………………………………………………….166
7. ADJUSTING BOOM KICKOUT CONTROL LINKAGE……………………………………………………..167
8. ADJUSTING WINCH CONTROL LINKAGE……………………………………………………………168
MEASURING POWER TRAIN OIL PRESSURE……………………………………………………………….170
MEASURING COUNTERWEIGHT OIL PRESSURE……………………………………………………………..172
MEASURING WINCH OIL PRESSURE…………………………………………………………………….173
MEASURING LEAKAGE INSIDE CYLINDER………………………………………………………………..176
ADJUSTING CLEARANCE OF IDLER…………………………………………………………………….177
TROUBLESHOOTING………………………………………………………………………………..179
POINTS TO REMEMBER WHEN TROUBLESHOOTING……………………………………………………….180
SEQUENCE OF EVENTS IN TROUBLESHOOTING…………………………………………………………181
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE……………………………………………….182
CHECKS BEFORE TROUBLESHOOTING………………………………………………………………..190
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)……………………………………………………..191
METHOD OF USING TROUBLESHOOTING CHARTS…………………………………………………….192
S-1 Starting performance is poor (starting always takes time)………………………………..196
S-2 Engine does not start………………………………………………………………..197
(1) Engine does not turn……………………………………………………………..197
(2) Engine turns but no exhaust smoke comes out (fuel is not being injected)……………….198
(3) Exhaust smoke comes out, but engine does not start (Fuel is being injected)…………….199
S-3 Engine does not pick up smoothly………………………………………………………200
S-4 Engine stops during operations………………………………………………………..201
S-5 Engine does not rotate smoothly (hunting)………………………………………………202
S-6 Engine lacks output (no power)………………………………………………………..203
S-7 Exhaust smoke is black……………………………………………………………….204
S-8 Oil consumption is excessive (or exhaust smoke is blue)………………………………….205
S-9 Oil becomes contaminated quickly………………………………………………………206
S-10 Fuel consumption is excessive………………………………………………………..207
S-11 Oil is in cooling water……………………………………………………………..208
S-12 Oil pressure caution lamp lights up (drop in oil pressure)………………………………209
S-13 Oil level rises (water, fuel in oil)………………………………………………….210
S-14 Water temperature becomes too high (overheating)……………………………………….211
S-15 Abnormal noise is made………………………………………………………………212
S-16 Vibration is excessive………………………………………………………………213
TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEM (H MODE)………………………………………..215
H-1 Torque converter oil temperature is too high……………………………………………216
H-2 Machine does not move………………………………………………………………..218
H-3 Machine lacks power or speed………………………………………………………….220
H-4 Machine moves when engine is started…………………………………………………..221
H-5 Excessive time lag when starting machine or shifting gear………………………………..221
H-6 Excessive shock when starting off or shifting gear………………………………………222
H-7 Machine moves in only one direction (FORWARD or REVERSE)…………………………………223
H-8 Steering clutch is not disengaged……………………………………………………..224
H-9 Steering clutch slips………………………………………………………………..225
H-10 Steering brake does not work…………………………………………………………226
H-11 Lack of power, speed when retract counterweight………………………………………..227
H-12 lmpossible to retract counterweight…………………………………………………..228
H-13 Excessive hydraulic drift of counterweight cylinder…………………………………….229
H-14 Defective boom RAISE, LOWER (speed, raising force, lowering force………………………..230
H-15 Defective hook RAISE, LOWER (speed, raising force, lowering force)……………………….231
H-16 Excessive hydraulic drift of boom…………………………………………………….232
H-17 Excessive hydraulic drift of hook…………………………………………………….233
H-18 Play when operating hook…………………………………………………………….234
H-19 Play when operating boom…………………………………………………………….235
H-20 Excessive time lag when operating hook………………………………………………..236
H-21 Excessive time lag when operating boom………………………………………………..237
H-22 Excessive inching amount…………………………………………………………….238
H-23 Winch free fall does not work………………………………………………………..239
H-24 Winch overheats…………………………………………………………………….240
H-25 Excessive noise when operating winch clutch, brake……………………………………..241
H-26 Control lever is heavy………………………………………………………………242
30 DISASSEMBLY AND ASSEMBLY………………………………………………………………………… 0
METHOD OF USING MANUAL………………………………………………………………………….245
PRECAUTIONS WHEN CARRYING OUT OPERATION…………………………………………………………..247
SPECIAL TOOL LIST………………………………………………………………………………249
STARTING MOTOR REMOVAL AND INSTALLATION…………………………………………………………..253
ALTERNATOR REMOVAL AND INSTALLATION………………………………………………………………254
ENGINE OIL COOLER REMOVAL AND INSTALLATION………………………………………………………..255
WATER PUMP REMOVAL AND INSTALLATION………………………………………………………………256
FUEL INJECTION PUMP REMOVAL……………………………………………………………………..257
FUEL INJECTION PUMP INSTALLATION…………………………………………………………………258
NOZZLE HOLDER REMOVAL AND INSTALLATION……………………………………………………………259
TURBOCHARGER REMOVAL AND INSTALLATION…………………………………………………………….260
THERMOSTAT REMOVAL AND INSTALLATION………………………………………………………………261
ENGINE FRONT SEAL REMOVAL AND INSTALLATION………………………………………………………..262
ENGINE REAR SEAL REMOVAL………………………………………………………………………..263
ENGINE REAR SEAL INSTALLATION……………………………………………………………………264
CYLINDER HEAD REMOVAL…………………………………………………………………………..267
CYLINDER HEAD INSTALLATION………………………………………………………………………270
RADIATOR, POWER TRAIN OIL COOLER REMOVAL AND INSTALLATION…………………………………………..273
ENGINE REMOVAL…………………………………………………………………………………274
ENGINE INSTALLATION…………………………………………………………………………….278
TORQUE CONVERTER REMOVAL………………………………………………………………………..279
TORQUE CONVERTER INSTALLATION……………………………………………………………………281
TORQUE CONVERTER DISASSEMBLY…………………………………………………………………….283
TORQUE CONVERTER ASSEMBLY……………………………………………………………………….288
TORQFLOW TRANSMISSION REMOVAL……………………………………………………………………294
TORQFLOW TRANSMISSION INSTALLATION……………………………………………………………….296
TORQFLOW TRANSMISSION DISASSEMBLY………………………………………………………………..298
TORQFLOW TRANSMISSION ASSEMBLY…………………………………………………………………..309
TRANSMISSION CONTROL VALVE REMOVAL AND INSTALLATION………………………………………………..323
TRANSMISSION CONTROL VALVE DISASSEMBLY……………………………………………………………324
TRANSMISSION CONTROL VALVE ASSEMBLY………………………………………………………………326
TRANSMISSION LUBRICATION VALVE REMOVAL AND INSTALLATION…………………………………………….328
TRANSMISSION PUMP REMOVAL AND INSTALLATION………………………………………………………..329
BEVEL GEAR, SHAFT REMOVAL……………………………………………………………………….330
BEVEL GEAR, SHAFT INSTALLATION…………………………………………………………………..333
STEERING CLUTCH REMOVAL…………………………………………………………………………337
STEERING CLUTCH INSTALLATION…………………………………………………………………….340
STEERING CLUTCH DISASSEMBLY……………………………………………………………………..343
STEERING CLUTCH ASSEMBLY………………………………………………………………………..345
STEERING BRAKE VALVE DISASSEMBLY…………………………………………………………………348
STEERING BRAKE VALVE ASSEMBLY……………………………………………………………………350
FINAL DRIVE DISASSEMBLY…………………………………………………………………………352
FINAL DRIVE ASSEMBLY……………………………………………………………………………356
TRACK SHOE REMOVAL……………………………………………………………………………..361
TRACK SHOE INSTALLATION…………………………………………………………………………363
TRACK FRAME REMOVAL…………………………………………………………………………….364
TRACK FRAME INSTALLATION………………………………………………………………………..365
RECOIL SPRING REMOVAL…………………………………………………………………………..366
RECOIL SPRING INSTALLATION………………………………………………………………………369
RECOIL SPRING DISASSEMBLY……………………………………………………………………….372
RECOIL SPRING ASSEMBLY………………………………………………………………………….373
IDLER REMOVAL AND INSTALLATION…………………………………………………………………..374
TRACK ROLLER REMOVAL AND INSTALLATION…………………………………………………………….375
CARRIER ROLLER REMOVAL AND INSTALLATION…………………………………………………………..376
RIGHT, CENTER GATE FRAME REMOVAL…………………………………………………………………377
RIGHT, CENTER GATE FRAME INSTALLATION…………………………………………………………….379
COUNTERWEIGHT FRAME REMOVAL……………………………………………………………………..381
COUNTERWEIGHT FRAME INSTALLATION…………………………………………………………………383
BOOM, LEFT GATE FRAME REMOVAL AND INSTALLATION…………………………………………………….385
WINCH DISMOUNTING………………………………………………………………………………386
WINCH MOUNTING…………………………………………………………………………………388
WINCH CONTROL AND PPC VALVE DISMOUNTING AND MOUNTING……………………………………………….390
HIGH/LOW VALVE DISMOUNTING AND MOUNTING…………………………………………………………..391
WINCH DISASSEMBLY………………………………………………………………………………392
・ WINCH……………………………………………………………………………………392
・ BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH…..418
・ BOOM BRAKE, HOOK BRAKE…………………………………………………………………….421
・ PPC VALVE………………………………………………………………………………..424
・ CONTROL………………………………………………………………………………….426
・ HI, LO SELECTOR VALVE……………………………………………………………………..429
・ FLOW DIVIDER VALVE………………………………………………………………………..431
・ STRAINER ASSEMBLY…………………………………………………………………………432
・ FILTER ASSEMBLY…………………………………………………………………………..433
WINCH ASSEMBLY…………………………………………………………………………………434
・ WINCH……………………………………………………………………………………434
・ BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH…..434
・ BOOM BRAKE, HOOK BRAKE…………………………………………………………………….438
・ PPC VALVE ASSEMBLY………………………………………………………………………..441
・ CONTROL………………………………………………………………………………….444
・ HI, LO SELECTOR VALVE……………………………………………………………………..447
・ FLOW DIVIDER VALVE………………………………………………………………………..449
・ STRAINER…………………………………………………………………………………450
・ FILTER…………………………………………………………………………………..451
・ WINCH……………………………………………………………………………………452
WINCH PUMP DISMOUNTING AND MOUNTING………………………………………………………………481
COUNTERWEIGHT PUMP REMOVAL AND INSTALLATION……………………………………………………….482
COUNTERWEIGHT CYLINDER REMOVAL AND INSTALLATION……………………………………………………483
COUNTERWEIGHT CYLINDER DISASSEMBLY……………………………………………………………….484
COUNTERWEIGHT CYLINDER ASSEMBLY………………………………………………………………….486
COUNTERWEIGHT CONTROL VALVE REMOVAL AND INSTALLATION……………………………………………….488
COUNTERWEIGHT CONTROL VALVE DISASSEMBLY…………………………………………………………..490
COUNTERWEIGHT CONTROL VALVE ASSEMBLY……………………………………………………………..492
CAUTION WHEN ASSEMBLING SHEAVE BLOCK……………………………………………………………..494
CAB REMOVAL AND INSTALLATION…………………………………………………………………….495
40 MAINTENANCE STANDARD……………………………………………………………………………. 0
ENGINE MOUNT…………………………………………………………………………………..498
PTO…………………………………………………………………………………………..500
TORQUE CONVERTER……………………………………………………………………………….502
TORQFLOW TRANSMISSION…………………………………………………………………………..504
TRANSMISSION CONTROL VALVE………………………………………………………………………506
TRANSMISSION LUBRICATION VALVE…………………………………………………………………..508
TRANSMISSION PUMP………………………………………………………………………………509
BEVEL GEAR SHAFT……………………………………………………………………………….510
STEERING CLUTCH………………………………………………………………………………..512
STEERING BRAKE…………………………………………………………………………………514
STEERING AND BRAKE CONTROL VALVE…………………………………………………………………516
STEERING MAIN RELIEF VALVE………………………………………………………………………518
STEERING PUMP………………………………………………………………………………….520
FINAL DRIVE……………………………………………………………………………………522
TRACK FRAME……………………………………………………………………………………524
RECOIL SPRING………………………………………………………………………………….525
TRACK…………………………………………………………………………………………526
LDLER…………………………………………………………………………………………528
TRACK ROLLER…………………………………………………………………………………..530
CARRIER ROLLER…………………………………………………………………………………532
SUSPENSION…………………………………………………………………………………….533
WINCH PUMP…………………………………………………………………………………….534
COUNTERWEIGHT PUMP……………………………………………………………………………..535
HIGH-LOW VALVE…………………………………………………………………………………536
PPC VALVE……………………………………………………………………………………..537
FLOW DIVIDER VALVE……………………………………………………………………………..538
WINCH…………………………………………………………………………………………540
WINCH CLUTCH…………………………………………………………………………………..542
WINCH BRAKE……………………………………………………………………………………544
COUNTERWEIGHT CONTROL VALVE……………………………………………………………………..546
COUNTERWEIGHT CYLINDER………………………………………………………………………….547
SLOW RETURN VALVE………………………………………………………………………………548
COUNTERWEIGHT………………………………………………………………………………….549
BOOM, HOOK AND SHEAVE…………………………………………………………………………..550