This Complete Service Repair Workshop Manual PDF Download for the Komatsu D85C-21 Pipelayer (For -50°C SPECIFICATION) (SN: 36551 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 D85C-21 Pipelayer
(For -50°C SPECIFICATION)
Serial Numbers : 36551 and up
D85C-21 mount the S6D125-2 engine.
TABLE OF CONTENTS :
01 GENERAL
10 STRUCTURE AND FUNCTION
20 TESTING AND ADJUSTING
30 DISASSEMBLY AND ASSEMBLY
40 MAINTENANCE STANDARD
MANUAL SPECIFICATION :
File Format : PDF
Language : English
Bookmarked : Yes
Searchable : Yes
Printable : Yes
Product Code : SEBM014700
Total Pages : 523
This manual 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 manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having PDF files instead of a hard-printed manual is that you can use the Search feature in Acrobat to find just what your looking for and just print out the exact pages you need or all manual.
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COVER
CONTENTS
01 GENERAL
GENERAL ASSEMBLY DRAWING
SPECIFICATIONS
WEIGHT TABLE
TABLE OF OIL AND COOLANT QUANTITIES
10 STRUCTURE AND FUNCTION
RADIATOR SHUTTER
POWER TRAIN
POWER TRAIN HYDRAULIC PIPING DIAGRAM
POWER TRAIN HYDRAULIC SYSTEM DIAGRAM
POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM
PTO
TORQUE CONVERTER
TRANSMISSION CONTROL
TORQFLOW TRANSMISSION
TRANSMISSION CONTROL VALVE
TRANSMISSION LUBRICATION VALVE
STEERING, BRAKE CONTROL
BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE
STEERING MAIN LELIEF VALVE
STEERING AND BRAKE CONTROL VALVE
STEERING BRAKE
TRANSMISSION AND STEERING OIL STRAINER
TRANSMISSION AND STEERING OIL FILTER
FINAL DRIVE
TRACK GROUP
SUSPENSION
GATE FRAME
WINCH CONTROL
HYDRAULIC CIRCUIT DIAGRAM FOR WINCH
WINCH
POWER TRAIN OF WINCH
HIGH-LOW VALVE
PPC VALVE
FLOW DIVIDER VALVE
WINCH OIL FILTER
WINCH OIL STRAINER
COUNTERWEIGHT HYDRAULIC TANK
COUNTERWEIGHT PIPING
COUNTERWEIGHT CONTROL
HYDRAULIC CIRCUIT SCHEMATICS FOR COUNTERWEIGHT
HYDRAULIC CIRCUIT DIAGRAM FOR COUNTERWEIGHT
COUNTERWEIGHT
COUNTERWEIGHT CONTROL VALVE
BOOM
SAFETY DEVICE
CAB
HEATER
ACTUAL ELECTRICAL WIRING DIAGRAM
ELECTRICAL CIRCUIT DIAGRAM
20 TESTING AND ADJUSTING
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS
TOOLS FOR TESTING, ADJUSTING, AND TROUBLESHOOTING
ADJUSTING VALVE CLEARANCE
MEASURING COMPRESSION PRESSURE
TESTING AND ADJUSTING FUEL INJECTION TIMING
MEASURING ENGINE OIL PRESSURE
MEASURING EXHAUST COLOR
MEASURING EXHAUST TEMPERATURE
TESTING AND ADJUSTING ALTERNATOR BELT TENSION
MEASURING BLOW-BY PRESSURE
MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)
MEASURING ENGINE SPEED
MEASURING TORQUE CONVERTER STALL SPEED
BLEEDING AIR
ADJUSTING STROKE, LINKAGE
1. ADJUSTING FUEL CONTROL LINKAGE
2. ADJUSTING GEAR SHIFT LEVER LINKAGE
3. ADJUSTING STEERING LEVER LINKAGE
4. ADJUSTING TRAVEL OF BRAKE PEDAL
5. ADJUSTING BRAKE PEDAL LINKAGE
6. ADJUSTING COUNTERWEIGHT CONTROL LINKAGE
7. ADJUSTING BOOM KICKOUT CONTROL LINKAGE
8. ADJUSTING WINCH CONTROL LINKAGE
MEASURING POWER TRAIN OIL PRESSURE
MEASURING COUNTERWEIGHT OIL PRESSURE
MEASURING WINCH OIL PRESSURE
MEASURING LEAKAGE INSIDE CYLINDER
ADJUSTING CLEARANCE OF IDLER
TROUBLESHOOTING
POINTS TO REMEMBER WHEN TROUBLESHOOTING
SEQUENCE OF EVENTS IN TROUBLESHOOTING
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE
CHECKS BEFORE TROUBLESHOOTING
TROUBLESHOOTING OF ENGINE SYSTEM (S MODE)
METHOD OF USING TROUBLESHOOTING CHARTS
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 SMOKE COMES OUT (FUEL IS NOT BEING INJECTED)
(3) EXHAUST SMOKE 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 NT ROTATE SMOOTHLY (HUNTING)
S-6 ENGINE LACKS OUTPUT (NO POWER)
S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION)
S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE 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 CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE)
S-13 OIL LEVEL RISES (WATER, FUEL IN OIL)
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)
H-1 TORQUE CONVERTER OIL TEMPERATURE IS TOO HIGH
H-2 MACHINE DOES NOT MOVE
H-3 MACHINE LACKS POWER OR SPEED
H-4 MACHINE MOVES WHEN ENGINE IS STARTED
H-5 EXCESSIVE TIME LAG WHEN STARTING MACHINE OR SHIFTING GEAR
H-6 EXCESSIVE SHOCK WHEN STARTING OFF OR SHIFTING GEAR
H-7 MACHINE MOVES IN ONLY ONE DIRECTION (FORWARD OR REVERSE)
H-8 STEERING CLUTCH IS NOT DISENGAGED
H-9 STEERING CLUTCH SLIPS
H-10 STEERING BRAKE DOES NOT WORK
H-11 LACK OF POWER, SPEED WHEN RETRACT COUNTERWEIGHT
H-12 IMPOSSIBLE TO RETRACT COUNTERWEIGHT
H-13 EXCESSIVE HYDRAULIC DRIFT OF COUNTERWEIGHT CYLINDER
H-14 DEFECTIVE BOOM RAISE, LOWER (SPEED, RAISING FORCE, LOWERING FORCE)
H-15 DEFECTIVE HOOK RAISE, LOWER (SPEED, RAISING FORCE, LOWERING FORCE)
H-16 EXCESSIVE HYDRAULIC DRIFT OF BOOM
H-17 EXCESSIVE HYDRAULIC DRIFT OF HOOK
H-18 PLAY WHEN OPERATING HOOK
H-19 PLAY WHEN OPERATING BOOM
H-20 EXCESSIVE TIME LAG WHEN OPERATING HOOK
H-21 EXCESSIVE TIME LAG WHEN OPERATING BOOM
H-22 EXCESSIVE INCHING AMOUNT
H-23 WINCH FREE FALL DOES NOT WORK
H-24 WINCH OVERHEATS
H-25 EXCESSIVE NOISE WHEN OPERATING WINCH CLUTCH, BRAKE
H-26 CONTROL LEVER IS HEAVY
30 DISASSEMBLY AND ASSEMBLY
METHOD OF USING MANUAL
PRECAUTIONS WHEN CARRYING OUT OPERATION
SPECIAL TOOL LIST
STARTING MOTOR
REMOVAL AND INSTALLATION
ALTERNATOR
REMOVAL AND INSTALLATION
ENGINE OIL COOLER
REMOVAL AND INSTALLATION
WATER PUMP
REMOVAL AND INSTALLATION
FUEL INJECTION PUMP
REMOVAL
INSTALLATION
NOZZLE HOLDER
REMOVAL AND INSTALLATION
TURBOCHARGER
REMOVAL AND INSTALLATION
THERMOSTAT
REMOVAL AND INSTALLATION
ENGINE FRONT SEAL
REMOVAL AND INSTALLATION
ENGINE REAR SEAL
REMOVAL
INSTALLATION
CYLINDER HEAD
REMOVAL
INSTALLATION
RADIATOR, POWER TRAIN OIL COOLER
REMOVAL AND INSTALLATION
ENGINE
REMOVAL
INSTALLATION
TORQUE CONVERTER
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TORQFLOW TRANSMISSION
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION CONTROL VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
TRANSMISSION LUBRICATION VALVE
REMOVAL AND INSTALLATION
TRANSMISSION PUMP
REMOVAL AND INSTALLATION
BEVEL GEAR, SHAFT
REMOVAL
INSTALLATION
STEERING CLUTCH
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
STEERING BRAKE VALVE
DISASSEMBLY
ASSEMBLY
FINAL DRIVE
DISASSEMBLY
ASSEMBLY
TRACK SHOE
REMOVAL
INSTALLATION
TRACK FRAME
REMOVAL
INSTALLATION
RECOIL SPRING
REMOVAL
INSTALLATION
DISASSEMBLY
ASSEMBLY
IDLER
REMOVAL AND INSTALLATION
TRACK ROLLER
REMOVAL AND INSTALLATION
CARRIER ROLLER
REMOVAL AND INSTALLATION
RIGHT, CENTER GATE FRAME
REMOVAL
INSTALLATION
COUNTERWEIGHT FRAME
REMOVAL
INSTALLATION
BOOM, LEFT GATE FRAME
REMOVAL AND INSTALLATION
WINCH
DISMOUNTING
MOUNTING
WINCH CONTROL AND PPC VALVE
DISMOUNTING AND MOUNTING
HIGH/LOW VALVE
DISMOUNTING AND MOUNTING
WINCH
DISASSEMBLY
・WINCH
・BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH
・BOOM BRAKE, HOOK BRAKE
・PPC VALVE
・CONTROL
・HI, LO SELECTOR VALVE
・FLOW DIVIDER VALVE
・STRAINER
・FILTER
ASSEMBLY
・WINCH
・BOOM RAISE CLUTCH, BOOM LOWER CLUTCH, HOOK RAISE CLUTCH, HOOK LOWER CLUTCH, HI CLUTCH, LO CLUTCH
・BOOM BRAKE, HOOK BRAKE
・PPC VALVE ASSEMBLY
・CONTROL
・HI, LO SELECTOR VALVE
・FLOW DIVIDER VALVE
・STRAINER
・FILTER
・WINCH
WINCH PUMP
DISMOUNTING AND MOUNTING
COUNTERWEIGHT PUMP
REMOVAL AND INSTALLATION
COUNTERWEIGHT CYLINDER
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
COUNTERWEIGHT CONTROL VALVE
REMOVAL AND INSTALLATION
DISASSEMBLY
ASSEMBLY
CAUTION WHEN ASSEMBLING SHEAVE BLOCK
BLOCK
CAB
REMOVAL AND INSTALLATION
40 MAINTENANCE STANDARD
ENGINE MOUNT
PTO
TORQUE CONVERTER
TORQFLOW TRANSMISSION
TRANSMISSION CONTROL VALVE
TRANSMISSION LUBRICATION VALVE
TRANSMISSION PUMP
BEVEL GEAR SHAFT
STEERING CLUTCH
STEERING BRAKE
STEERING AND BRAKE CONTROL VALVE
STEERING MAIN RELIEF VALVE
STEERING PUMP
FINAL DRIVE
TRACK FRAME
RECOIL SPRING
TRACK
IDLER
TRACK ROLLER
CARRIER ROLLER
SUSPENSION
WINCH PUMP
COUNTERWEIGHT PUMP
HIGH-LOW VALVE
PPC VALVE
FLOW DIVIDER VALVE
WINCH
WINCH CLUTCH
WINCH BRAKE
COUNTERWEIGHT CONTROL VALVE
COUNTERWEIGHT CYLINDER
SLOW RETURN VALVE
COUNTERWEIGHT
BOOM, HOOK AND SHEAVE
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