PDF Shop Manual Komatsu D85EX-18 D85PX-18 Bulldozer - 4 MB
This extensive shop manual is the ultimate resource for servicing the Komatsu D85EX-18 and D85PX-18 bulldozers.
It contains all the technical information required for disassembly, repair, and reassembly of the machine's major components.
Technicians will find detailed specifications, troubleshooting charts, and step-by-step procedures to perform any task with precision.
Ensure your bulldozer is maintained to factory standards with this indispensable guide.
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--- Page 1 ---
SEN06901-05
BULLDOZER D85EX -18
D85PX -18
SERIAL NUMBERS 25001 and up
--- Page 3 ---
Safety Notice for Operation 00 Index and Foreword
• Before starting work, shut down the engine. When working
on or around a rotating part, in particular, shut down the
engine. When checking the machine without shutting down
the engine (measuring oil pressure, revolving speed, tem-
perature, etc.), take extreme care not to get caught in ro-
tating parts or moving parts.
• When raising a heavy component (heavier than 20kg), use
a hoist or crane. Before starting work, check that the slings
(wire ropes, webbing slings, chains, and hooks) are free
from damage. Always use slings which have ample ca-
pacity and install them to proper places. Operate the hoist
or crane slowly to prevent the component from hitting any
other part. Do not work with any part still raised by the
hoist or crane.
• When removing a part which is under internal pressure or
under reaction force of a spring, always leave 2 bolts in di-
agonal positions. Loosen those 2 bolts gradually and alter-
nately to release the pressure, and then remove the part.
• When removing components, do not break or damage the
electrical wiring. Damaged wiring may cause a fire.
,&
• When removing piping, do not spill the fuel or oil. If any
fuel or oil drips onto the floor, wipe it off immediately. Fuel
or oil on the floor can cause you to slip and can even cause fires.
• Do not use gasoline to wash parts as a general rule. Do not use gasoline to clean electrical parts, in partic-
ular.
• Install the disassembled parts again to the original position. Replace the damaged parts or the parts that
cannot be used again with new ones. Before you connect the hoses or wiring harnesses, make sure that
they do not touch and give damage to other parts when you operate the machine.
REMARK
When you replace the removed or disassembled parts with new ones, refer the parts book to find out the
part number.
• When installing high pressure hoses and tubes, make sure that they are not twisted. Damaged hoses and
tubes are dangerous, so be extremely careful when installing hoses and tubes for high pressure circuits. In
addition, check that high pressure hoses and tubes are correctly installed.
• When assembling or installing parts, always tighten them to the specified torques. When installing protec-
tive parts such as guards, or parts which vibrate violently or rotate at high speed, check again that they are
installed correctly.
• Never insert your fingers or hand when aligning 2 holes. Be careful not to get your fingers caught in a hole.
• Check that the measuring tools are correctly installed when measuring hydraulic pressure.
• Take care when removing or installing the tracks of track-type machines. Since the track shoe may sepa-
rate suddenly when you remove it, never let anyone stand at either end of the track shoe.
• If the engine is operated for a long time in a closed place
with poor ventilation, it may cause gas poisoning. Open
the windows and doors to ventilate the place well.
,&
00-28 D85EX-18, D85PX-18
--- Page 4 ---
00 Index and Foreword Disconnect and Connect Push-Pull Type Coupler
Connection
Hold the tightening adapter part, and push body (2) straight un-
til sliding prevention ring (1) contacts contact surface (a) of the
hexagonal part at the male end.
D85EX-18, D85PX-18 00-57
--- Page 5 ---
Conversion Table 00 Index and Foreword
1 kgf/cm2 = 14.2233 lb/in2
0 1 2 3 4 5 6 7 8 9
30 426.7 440.9 455.1 469.4 483.6 497.8 512.0 526.3 540.5 554.7
40 568.9 583.2 597.4 611.6 625.8 640.1 654.3 668.5 682.7 696.9
50 711.2 725.4 739.6 753.8 768.1 782.3 796.5 810.7 825.0 839.2
60 853.4 867.6 881.8 896.1 910.3 924.5 938.7 953.0 967.2 981.4
70 995.6 1010 1024 1038 1053 1067 1081 1095 1109 1124
80 1138 1152 1166 1181 1195 1209 1223 1237 1252 1266
90 1280 1294 1309 1323 1337 1351 1365 1380 1394 1408
100 1422 1437 1451 1465 1479 1493 1508 1522 1536 1550
110 1565 1579 1593 1607 1621 1636 1650 1664 1678 1693
120 1707 1721 1735 1749 1764 1778 1792 1806 1821 1835
130 1849 1863 1877 1892 1906 1920 1934 1949 1963 1977
140 1991 2005 2020 2034 2048 2062 2077 2091 2105 2119
150 2134 2148 2162 2176 2190 2205 2219 2233 2247 2262
160 2276 2290 2304 2318 2333 2347 2361 2375 2389 2404
170 2418 2432 2446 2460 2475 2489 2503 2518 2532 2546
180 2560 2574 2589 2603 2617 2631 2646 2660 2674 2688
190 2702 2717 2731 2745 2759 2773 2788 2802 2816 2830
200 2845 2859 2873 2887 2901 2916 2930 2944 2958 2973
210 2987 3001 3015 3030 3044 3058 3072 3086 3101 3115
220 3129 3143 3158 3172 3186 3200 3214 3229 3243 3257
230 3271 3286 3300 3314 3328 3343 3357 3371 3385 3399
240 3414 3428 3442 3456 3470 3485 3499 3513 3527 3542
Temperature
Conversion of Fahrenheit to Celsius
• A simple way to convert a Fahrenheit temperature reading into a Celsius temperature reading or vice versa
is to see the number in the center column of the following table. The figures in the center of the following
table show the temperatures in both Fahrenheit and Celsius.
• When converting from Fahrenheit to Celsius degrees, consider the center column to be a table of Fahren-
heit temperatures and read the corresponding Celsius temperature in the column at the left.
• When converting from Celsius to Fahrenheit degrees, consider the center column to be a table of Celsius
values, and read the corresponding Fahrenheit temperature on the right.
1 °C = 33.8 °F
°C °F °C °F °C °F °C °F
-40.4 -40 -40.0 -11.7 11 51.8 7.8 46 114.8 27.2 81 177.8
-37.2 -35 -31.0 -11.1 12 53.6 8.3 47 116.6 27.8 82 179.6
-34.4 -30 -22.0 -10.6 13 55.4 8.9 48 118.4 28.3 83 181.4
-31.7 -25 -13.0 -10.0 14 57.2 9.4 49 120.2 28.9 84 183.2
-28.9 -20 -4.0 -9.4 15 59.0 10.0 50 122.0 29.4 85 185.0
-28.3 -19 -2.2 -8.9 16 60.8 10.6 51 123.8 30.0 86 186.8
00-86 D85EX-18, D85PX-18
--- Page 6 ---
10 Structure and Function
D85EX-18, D85PX-18 10-1
--- Page 7 ---
Component Parts of Urea SCR System 10 Structure and Function
DEF Tank Sensor
Structure of DEF Tank Sensor
REMARK
The shape is subject to machine models.
1: Connector 3: Temperature sensing part
2: Concentration Sensing part 4: Level sensing part
Function of DEF Tank Sensor
• This sensor is installed to DEF tank and outputs DEF level, DEF concentration, and DEF temperature
through CAN communication.
• DEF level and DEF concentration are measured by using ultrasonic wave.
• When the tank is frozen or empty, DEF level and DEF concentration are not measured.
10-30 D85EX-18, D85PX-18
--- Page 8 ---
10 Structure and Function Component Parts of Engine System
General View and Sectional View
A: EGR gas inlet D: Coolant outlet
B: EGR gas outlet (to EGR valve) E: Air vent
C: Coolant inlet F: Air vent
1: Header plate 3: Inner fin
2: Flat tube 4: Case
Operation of EGR Cooler
• EGR gas enters through (A) and flows through flat tubes (2) (9 pieces).
• Coolant enters through (C), flows outside of flat tubes (2) in case (4), and goes out through (D).
• Flat tube (2) has inner fins (3), thus EGR gas is cooled efficiently and discharged through EGR gas outlet
(B).
KCCV System
KCCV
Abbreviation for KOMATSU Closed Crankcase Ventilation
Layout Drawing of KCCV System
REMARK
The shape is subject to machine models.
D85EX-18, D85PX-18 10-59
--- Page 9 ---
Component Parts of Cooling System 10 Structure and Function
Safety Valve of Cooling Fan Motor
Function of Safety Valve of Cooling Fan Motor
The pressure in motor port (P) may increase when the engine
is started, etc. Safety valve (1) is installed to protect the fan
system circuit in this case.
Operation of Cooling Fan Motor Safety Valve
When the pressure in port (P) exceeds the cracking pressure of
safety valve (1), valve (2) of safety valve (1) opens to release
the pressurized oil into port (T). Occurrence of abnormally high
pressure in port (P) is prevented by this operation.
10-88 D85EX-18, D85PX-18
--- Page 10 ---
10 Structure and Function Component Parts of Control System
25 Transmission R clutch fill switch Input
26 (*1) -
27 Blade control lever lower switch (NC) Input
28 Backup Alarm Input
29 GND (pulse) -
30 Transmission output shaft speed sensor Input
31 (*1) -
32 CAN0_H Input and output
33 CAN1_H Input and output
34 RS232C GND -
35 Transmission F clutch fill switch Input
36 (*1) -
37 Blade control lever lower switch (NO) Input
38 (*1) -
39 GND (pulse) -
40 Cooling fan speed sensor Input
*1: Never connect these pins, otherwise it may cause malfunction or failures.
*2: Applicable Machine: 25001 to 25152
*3: Applicable Machine: 25153 and up
DRC26-40P(B)(PTCN3)
Input and output sig-
Pin No. Signal name
nals
1 Continuous power supply (24 V) Input
2 Power supply (24 V) Input
3 GND (solenoid common) -
4 For battery relay drive Output
5 Left steering EPC valve Output
6 Transmission 3rd clutch ECMV Output
7 Pitch selector solenoid valve Output
8 HSS pump TVC solenoid valve Output
9 (*1) -
10 Work equipment iB switch (NO) Input
11 Continuous power supply (24 V) Input
12 Power supply (24 V) Input
13 GND (solenoid common) Input
14 Starting switch ACC signal Input
15 Right steering EPC valve Output
16 (*1) -
17 Cooling fan reverse solenoid Output
18 Cooling fan control solenoid Output
D85EX-18, D85PX-18 10-117
--- Page 11 ---
Component Parts of Hydraulic System 10 Structure and Function
10. Since springs (3) and (4) are 2-stage springs, the position-
al relation between pump discharged pressure (PP) and
servo piston (9) becomes a polygonal line, and the relation
between pump discharged pressure (PP) and pump dis-
charged volume (Q) is as shown in the figure.
Variable Throttle Valve
Function of Variable Throttle Valve
• Since the work equipment and HSS pump controls itself with its own pressure, the swash plate tends to
respond quickly at high pressure and slowly at low pressure.
• The variable throttle valve reduces the swash plate speed in the ranges from the minimum to maximum an-
gle and from the maximum to minimum angle, when the pressure is high.
The impacts applied to the rods of the work equipment and HSS pump are reduced to prevent the high
stress from being generated.
• When the pressure is high, the variable throttle valve reduces the speed of the swash plate moving from the
minimum to maximum angles in order to restrict sudden increase of the suction volume.
By this operation, cavitation at the suction port caused by sudden increase of the suction volume is preven-
ted.
• The variable throttle valve has the characteristics shown in
the figure, and it decreases the open area when the pres-
sure is high, and increases the open area when the pres-
sure is low.
It increases the response speed of the swash plate at low
pressure, and secures the response during work.
10-146 D85EX-18, D85PX-18
--- Page 12 ---
10 Structure and Function Component Parts of Hydraulic System
Operation of Control Valve During Mixed Operation
During Mixed Operation of Steering System and Work Equipment
REMARK
The figure shows the steering and blade lift valve during combined operation.
D85EX-18, D85PX-18 10-175
--- Page 13 ---
Component Parts of Power Train System 10 Structure and Function
Sectional View (A-A)
5: Transmission input shaft 12: Clutch piston
6: R sun gear (number of teeth: 30) 13: F planetary pinion (number of teeth: 20)
7: Pinion shaft 14: 3rd planetary pinion (number of teeth: 30)
8: R ring gear (number of teeth: 70) 15: 3rd ring gear (number of internal teeth: 76, number
9: R planetary pinion (number of teeth: 20) of external teeth: 90)
10: Disc 16: 2nd sun gear (number of teeth: 35)
11: Plate 17: 1st planetary pinion (number of teeth: 18)
18: 1st sun gear (number of teeth: 39)
10-204 D85EX-18, D85PX-18
--- Page 14 ---
10 Structure and Function Component Parts of Power Train System
Operation When Direction is in “Reverse” and Steering is “LEFT Turn”
A: Transmission output C: Left bevel gear shaft output (= - A + B)
B: HSS motor output D: Right bevel gear shaft output (= - A - B)
REMARK
When the PCCS lever is set to “LEFT turn” while it is in REVERSE, HSS motor (7) rotates counterclockwise
when it is viewed from the left side of the machine.
Power from HSS motor (7) (counterclockwise rotation when it is
Power from transmission (REVERSE)
viewed from left side of machine)
↓ ↓
Bevel pinion (1) Drive gear (8)
↓ ↓
Bevel gear (2) Gear D (9) → ↓
↓ ↓ ↓
D85EX-18, D85PX-18 10-233
--- Page 15 ---
Layout Drawing of Fixed Multi-Shank Ripper 10 Structure and Function
Layout Drawing of Fixed Multi-Shank Ripper
1: Control valve 3: Ripper cylinder
2: Branch block
10-262 D85EX-18, D85PX-18
--- Page 16 ---
10 Structure and Function Suspension
Function of Suspension
The track frame moves the front part up and down with the pivot shaft (3) at the rear end used as a pivot. The
equalizer bar (1) rocks with the center pin (2) used as a pivot, and is connected to the right and left track frames
with the side pins (4).
D85EX-18, D85PX-18 10-291
--- Page 17 ---
Standard Value Table for Machine: D85EX-18 20 Standard Value Table
Machine model D85EX-18
Engine SAA6D125E-7
Standard value for
Item Measurement condition Unit Repair limit
new machine
• Engine coolant tem- Fuel control di- 20.4 to 22.8 20.4 to 22.8
perature: 60 to al: MIN (Low
idle) position {208 to 232} {208 to 232}
100 °C
• Power train oil tem-
perature: 70 to 80 °C
Ripper lift relief MPa
• Hydraulic oil temper-
pressure Fuel control di- {kg/cm2}
ature: 45 to 55 °C 21.4 to 23.7 21.4 to 23.7
al: MAX (High
• Operating Mode: P idle) position {218 to 242} {218 to 242}
(Power mode)
• Ripper control lever:
RAISE
• Engine coolant tem- Fuel control di- 19.2 to 21.2 19.2 to 21.2
perature: 60 to al: MIN (Low
idle) position {196 to 216} {196 to 216}
100 °C
• Power train oil tem-
perature: 70 to 80 °C
LS pressure
• Hydraulic oil temper- MPa
(Work equipment ature: 45 to 55 °C
load sensing Fuel control di- {kg/cm2} 19.2 to 21.2 19.2 to 21.2
pressure) • Operating Mode: P al: MAX (High
(Power mode) idle) position {196 to 216} {196 to 216}
• Work equipment
control lever: Opera-
tion of blade RAISE
or blade tilt relief
• Engine coolant temperature: 60 to
100 °C
• Power train oil temperature: 70 to
80 °C
• Hydraulic oil temperature: 45 to
Control circuit oil
55 °C MPa 3.97±0.29 3.97±0.29
pressure
• Operating Mode: P (Power mode) {kg/cm2} {40.5±3.0} {40.5±3.0}
(HSS, PPC, Fan)
• Fuel control dial: MAX (High idle)
position
• Joystick (steering, directional, and
gear shift lever) (PCCS lever): NEU-
TRAL position
20-18 D85EX-18, D85PX-18
--- Page 18 ---
30 Testing and Adjusting Table of Contents
How to Clean DEF Pump ............................................................................................................... 30-90
Clean DEF Tank Mounting Part ............................................................................................................. 30-97
How to Clean DEF Tank Mounting Part .......................................................................................... 30-97
Adjust Decelerator Pedal ...................................................................................................................... 30-98
How to Adjust Decelerator Pedal.................................................................................................... 30-98
Power Train.................................................................................................................................................30-100
Examine Power Train Oil Pressure.......................................................................................................30-100
How to Examine Power Train Oil Pressure....................................................................................30-101
Adjust Transmission Output Shaft Speed Sensor.................................................................................30-112
How to Adjust Transmission Output Shaft Speed Sensor..............................................................30-112
Examine Brake Performance Simply....................................................................................................30-114
How to Examine Brake Performance Simply .................................................................................30-114
Adjust Brake Pedal ..............................................................................................................................30-115
How to Adjust Brake Pedal............................................................................................................30-115
Adjust Parking Brake Lever..................................................................................................................30-117
How to Adjust Parking Brake Lever...............................................................................................30-117
Move Machine by Parking Brake Release When Machine Does Not Travel .........................................30-119
How to Move Machine with Hydraulic Type Parking Brake Release System .................................30-119
How to Move Machine with Electric Type Parking Brake Release System ....................................30-120
Undercarriage and Frame ...........................................................................................................................30-122
Adjust Idler Clearance..........................................................................................................................30-122
How to Adjust Idler Clearance.......................................................................................................30-122
How to Adjust Idler Clearance Horizontally ...................................................................................30-122
How to Adjust Idler Clearance Vertically........................................................................................30-122
Examine and Adjust Track Tension ......................................................................................................30-124
How to Examine............................................................................................................................30-124
How to Adjust Track Tension .........................................................................................................30-124
Hydraulic System ........................................................................................................................................30-125
Release Remained Pressure in Hydraulic Circuit .................................................................................30-125
How to Release Remained Pressure in Hydraulic System ............................................................30-125
Examine and Adjust Work Equipment and HSS Oil Pressure...............................................................30-126
How to Examine Work Equipment and HSS Oil Pressure .............................................................30-126
How to Adjust Oil Pressure of Work Equipment and HSS .............................................................30-130
Examine Oil Pressure of Control Circuit ...............................................................................................30-131
How to Examine Oil Pressure in Control Circuit ............................................................................30-131
Examine PPC Valve Outlet Pressure....................................................................................................30-133
How to Examine Outlet Pressure in PPC Valve.............................................................................30-133
Bleed Air from HSS Pump....................................................................................................................30-136
How to Bleed Air from HSS Pump.................................................................................................30-136
Examine and Adjust Play of Work Equipment PPC Valve.....................................................................30-137
How to Examine Play of Work Equipment PPC Valve ...................................................................30-137
How to Adjust Play of Work Equipment PPC Valve .......................................................................30-138
Examine Cooling Fan Speed................................................................................................................30-139
How to Examine Cooling Fan Speed.............................................................................................30-139
Examine Cooling Fan Circuit Oil Pressure ...........................................................................................30-140
How to Examine Cooling Fan Circuit Oil Pressure ........................................................................30-140
Bleed Air in Cooling Fan Pump ............................................................................................................30-142
How to Bleed Air in Cooling Fan Pump .........................................................................................30-142
Examine Parts Which Cause Hydraulic Drift of Work Equipment..........................................................30-143
How to Examine Parts Which Cause Hydraulic Drift of Blade Lift Cylinder ....................................30-143
How to Examine the Parts Which Cause Hydraulic Drift of Blade Tilt Cylinder ..............................30-143
How to Examine the Parts Which Cause Hydraulic Drift of Ripper Lift Cylinder.............................30-144
Examine Oil Leakage from Work Equipment Cylinder ..........................................................................30-145
How to Examine Internal Oil Leakage of Work Equipment Cylinder ..............................................30-145
Bleed Air from Work Equipment Cylinders ...........................................................................................30-147
How to Bleed Air from Work Equipment Cylinder ..........................................................................30-147
Work Equipment .........................................................................................................................................30-148
Adjust Work Equipment Lock Lever .....................................................................................................30-148
D85EX-18, D85PX-18 30-3
--- Page 19 ---
Examine Blowby Pressure 30 Testing and Adjusting
2. Disconnect hose (1) on the KCCV blowby gas outlet side,
install plug B to the hose with clamp A4, and install cap C
to the KCCV hose insertion pipe side.
3 Clamp A4:
4.4±0.49 Nm {0.45±0.05 kgfm}
3. Disconnect hose (2) on the KCCV blowby gas inlet side,
install cap C to the KCCV hose insertion pipe side. Install
tool A2 and adapter A3 of the blowby checker A to hose
(2), and connect gauge A1.
3 Clamp A4:
4.4±0.49 Nm {0.45±0.05 kgfm}
4. Start engine, and refer to “Set and Operate Machine Moni-
tor” to display Adjustment ID: 0530 “Stall mode”.
5. Set the fuel control dial to MAX (High idle) position, and
measure the blowby pressure at the time when torque con-
verter stall is performed.
For standard values, see Standard Value Table, “Standard
Value Table for Engine”.
30-32 D85EX-18, D85PX-18
--- Page 20 ---
30 Testing and Adjusting Write Correction for Ash in Soot Accumulation to Engine Controller
Write Correction for Ash in Soot Accumulation to Engine Controller
k Check that there is no person or combustible material around the machine (particularly in the direc-
tion of the exhaust gas flows).
• When starting the engine, ash contained in engine oil accumulates in KCSF and increases filter differential
pressure.
• Since filter differential pressure is used for calculation of soot accumulation in the engine controller, in-
crease amount of differential pressure by ash needs to be corrected.
• Correction amount of filter differential pressure increased by ash is calculated in the engine controller as
“Soot Correction by Ash Influence”.
• When engine controller is replaced with the new one, “Soot Correction by Ash Influence” becomes default