When installing and removing the measuring instrument, take care not to touch a hot part. Run the engine at high idling and stall the torque converter and measure the intake air pressure boost pressure at this time. In the field, however, an approximate value can be obtained by stalling the torque converter. Open the right side cover of the engine.
Remove air intake connector boost pressure pick-up plug 1. Install and remove the measuring instrument after the exhaust manifold is cooled. Procedure for measuring maximum exhaust temperature for troubleshooting Operate the machine actually and measure the maximum exhaust temperature.
Accordingly, if any abnormal value is obtained, correct it by the following calculation. Remove exhaust temperature pick-up plug 2. Install sensor [1] and connect them to digital thermometer B.
Procedure for measuring exhaust temperature periodically for preventive maintenance a If the torque converter is stalled simply, the torque converter oil temperature is overheated before the exhaust temperature is stabilized. Accordingly, measure according to the following procedure. Raise the ripper lift cylinder to the stroke end with the ripper lever.
Press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. Just after the power train oil temperature gauge reads the red range, return the direction of the PCCS lever into neutral and lower the power train oil temperature.
When recording official data, use smoke meter C2. Measuring with handy smoke checker C1 1 Stock a sheet of filter paper to C1. Measuring with smoke meter C2 1 Insert probe of smoke meter C2 in the outlet of the exhaust pipe and fix it to the exhaust pipe with a clip. If the rocker arms cannot be moved, rotate the crankshaft one more turn. Open the engine left side cover. Remove air cleaner 1 and bracket 2. Move bracket 3 back and remove air intake connector 8.
Fixing adjustment screw 6 , tighten locknut 7. Remove all cylinder head covers 9. Move them toward the air intake manifold without removing them from the tube. Locknut: Rotate the crankshaft forward to bring the stamped 1. Turn the crankshaft forward by degrees each time and adjust the clearances of the air intake valve and exhaust valve of each cylinder according the firing order.
After finishing adjustment, return the removed parts. Cylinder head cover mounting bolt: 9. When measuring the compression pressure, take care not to burn yourself on the exhaust manifold, muffler, etc. Open the engine left upper side cover and remove the lower side cover. Move bracket 3 back and remove air intake connector 4. Remove all of 6 fuel high-pressure tubes 5 , and then remove the all clamps so that the tubes can be moved.
Install adapter N2 and connect it to compression gauge N1. After finishing measurement, return the removed parts. Injector assembly mounting bolt: Disconnect concentrated connector 9 E21 for the engine. Disconnect the concentrated connector for safety, although the fuel high-pressure tube is disconnected. Cover the connector on the controller side with a vinyl sheet, etc. Crank the engine with the starting motor and measure the compression pressure.
If the measured value is judged abnormal, check for increase of oil consumption, bad exhaust gas color, deterioration of oil, high deterioration speed of oil, etc. Remove the radiator drain cock cover. Install nozzle [1] of blow-by checker E to blow-by hose 1 and connect them to gauge [2]. Run the engine at high idling, stall the torque converter, and measure the blow-by pressure.
Run the engine at low idling and high idling and measure the engine oil pressure in each speed. If foreign matter enters this system, it can cause a trouble.
When testing and adjusting the fuel system, take care more than the past. If dust, etc. Since the common rail fuel injection system CRI consists of more precise parts than the conventional fuel injection pump and nozzle, it employs a high-efficiency special filter to prevent foreign matter from entering it. If a filter other than the genuine one is used, the fuel system may have a trouble. Accordingly, never use such a filter.
Low-pressure circuit: Feed pump — Fuel filter — Fuel supply pump High-pressure circuit: Fuel supply pump — Common rail — Fuel injector a The pressure in both low-pressure circuit and high-pressure circuit lowers to a safety level automatically 30 seconds after the engine is stopped. Accordingly, observe the following. Before testing the fuel system or removing its parts, wait at least 30 seconds after stopping the engine until the residual pressure in the fuel circuit is released.
Do not start the work just after stopping the engine since there is residual pressure. Run the engine at high idling and measure the fuel pressure. Since the pressure in the high-pressure circuit from the fuel supply pump to the common rail and fuel injector is very high, it cannot be measured. Open the left side cover of the engine and remove fuel pressure pick-up plug 1. Remove fuel filter 1 , fill with fuel, then install again. Portion b is the outlet port clean side after the fuel has been filtered, so never add fuel from hear.
Operate the priming pump to fill the filter with fuel. Remove air bleed plug 2 of the fuel filter and operate priming pump 4. When fuel comes out, install the plug. Air bleed plug: 7. There are the following two cases that the engine does not start up easily after bleeding air from CRI, Common Rail Injection System , i.
Thus the engine start-up becomes difficult. In that case, bleed air in the following manner. Air bleeding steps i Remove air bleeding plug 2 of fuel filter 1 and operate priming pump 4. Air bleeding plug: 7. Fuel pressure measuring plug: 3. Air bleeder: 4. Still continue to operate the priming pump until it becomes harder to operate and a relief sound of overflow valve 6 in the fuel supply pump is heard.
A high pitch sound it requires approx. Moreover try to start up the engine only after two minute pause. In that case, start the air bleeding steps once again from the beginning.
Loosen air bleeder 5 of the fuel supply pump and operate priming pump 4 90 to times. When fuel comes out, tighten the bleeder, then operate several times until the priming pump becomes stiff. Crank the engine with the starting motor and start the engine. The reduced cylinder mode operation is used when it is though that one of the engine cylinders is not giving normal output combustion.
It is a method to determine which cylinder is not operating normally. Adjusting a If the deflection is abnormal, adjust it according to the following procedure. Loosen the 2 alternator mounting bolts and the 1 adjustment rod set bolt. Loosen locknut 1 and turn adjustment nut 2 to move alternator 3 and adjust the belt tension. Tighten the 2 alternator mounting bolts and the 1 adjustment rod set bolt. Loosen the 2 compressor bracket mounting bolts. Loosen locknut 1 and turn adjustment nut 2 to move compressor 3 and adjust the belt tension.
Tighten the 2 compressor bracket mounting bolts. Adjusting decelerator pedal engine speed With the fuel control dial in the high idling position, press decelerator pedal 1 to stopper bolt 2 and check that the decelerator pedal engine speed is normal.
High idling engine speed Set the fuel control dial in the high idling position and check that the high idling engine speed is normal. Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and safety lock lever in the LOCK position. Measure the power train oil pressure under the following condition.
A nipple for measuring oil pressure is not installed as standard. List of oil pressure measuring points and gauges to be used. Measuring torque converter outlet pressure OUT 1 Connect hydraulic tester F2 to oil pressure pick-up nipple 1.
Measuring transmission main relief pressure TM 1 Connect oil pressure gauge [1] of hydraulic tester F1 to oil pressure pick-up nipple 2.
Measuring torque converter inlet pressure IN 1 Connect oil pressure gauge [1] of hydraulic tester F1 to oil pressure pick-up nipple 3. Measuring transmission forward clutch pressure FWD 1 Connect oil pressure gauge [1] of hydraulic tester F1 to oil pressure pick-up nipple 4. Since the torque converter will be stalled, press the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished. Measuring transmission reverse clutch pressure R 1 Connect oil pressure gauge [1] of hydraulic tester F1 to oil pressure pick-up nipple 5.
Measuring transmission 1st clutch pressure 1ST 1 Connect oil pressure gauge [1] of hydraulic tester F1 to oil pressure pick-up nipple 6.
Since the torque converter will be stalled, keep pressing the brake pedal securely. Do not raise the engine speed to high idling during measurement. Measuring transmission 2nd clutch pressure 2ND 1 Connect oil pressure gauge [1] of hydraulic tester F1 to oil pressure pick-up nipple 7.
Measuring transmission 3rd clutch pressure 3RD 1 Connect oil pressure gauge [1] of hydraulic tester F1 to oil pressure pick-up nipple 8. Measuring steering left brake pressure LB 1 Connect oil pressure gauge [1] of hydraulic tester F1 to oil pressure pick-up nipple 9. Remove the fuel tank undercover, and then remove transmission speed sensor 1 and cover 2 together. Taking care of the direction of cover 2 , install it and sensor 2 together again to HSS case 4.
Surfaces of cover and case: Gasket sealant LG Install cover 2 to HSS case 4 temporarily. Tighten sensor 1 until its tip touches the tooth tip of gear 5. Threads of sensor: Gasket sealant LG-5 4. Return sensor 1 from the above position by the specified angle.
Remove sensor 1 and cover 2 together and secure them with locknut 3. Nut: Set the blade and ripper in the travel position on a level place. Run the engine and set the parking brake lever in the FREE position.
If this test is carried out in the 1st gear position, the brake will be overloaded. Accordingly, be sure to carry out in the 2nd gear speed. Press the decelerator pedal and set the fuel control dial in the high idling position. Return the decelerator pedal slowly and check that the machine does not start when the engine speed reaches the high idling level.
Tighten the locknuts of the rods and cables securely, and bend the cotter pins securely. Adjust fitting dimension b of damper 2 so that the soroke of brake pedal 1 will be dimension a. Adjust fitting dimension c of rod 3 on the valve side, then connect to brake valve lever 4. Adjust fitting dimension d of rod 6 on the pedal side, then connect to brake pedal 1. Lightly push rod 3 on the valve side toward the rear of the machine, and turn only joint 7 to connect rods 3 and 6.
Joint: When brake pedal 1 released, adijust its play with dimension e between the poins of rod assembly 8. With brake pedal 1 released, check that brake pedal 1 is in contact with damper 2.
After adjusting the pedal, adjust the zero point of the brake potentiometer Adjustment mode: Assembling and installing lever assembly 1 Assemble lever assembly 9 and adjust the operation of limit switch Adjusting length of parking brake cable 1 Connect parking brake cable 11 to the lever and valve and adjust dimensions f and g. Check that the limit switch signal is normal at this time.
Escape with switch box Use H1 a If the machine cannot be moved because of a trouble in the electric system of the power train control unit travel direction, gear speed, steering , escape according to the following procedure. Set the all gear speed switches of switch assembly [1] in the OFF position and the direction switch in the P position to prevent the machine from starting suddenly.
The above work must be performed to avoid this problem. If the engine is started by this method, the neutral safety function does not work. Start the engine by this method only in an emergency. If the engine does not start in another case, be sure to carry out troubleshooting and repair the trouble. Escape with brake releasing device Use H2 a If the engine cannot be started and the parking brake cannot be released, escape according to the following procedure.
In this case, adjust the set pressure of the relief valve. Accordingly, work quickly. In this case, operate the volume pump again to raise the brake releasing pressure to the intial pressure. Lateral adjustment 1 Drive the machine 1 — 2 m on flat ground, and then measure clearance a between the track frame and guide plate at 4 places on both sides, inside, and outside.
Vertical adjustment 1 Measure clearance b, subtract 2 mm from it, and record the result quantity of adjustment. Do not loosen it more than 3 turns, however. Testing 1. Drive the machine slowly on a level place, then stop it. Place straight steel bar 1 between the idler and front carrier roller and measure clearance a between the bottom of the steel bar and shoe grouser.
Adjusting a If the track shoe tension is abnormal, adjust it according to the following procedure. Remove cover 2. When the tension is too high Loosen plug 3 to discharge the grease.
Since the high-pressure grease may spout out, do not loosen the plug more than 1 turn. When tension is low Add grease through grease fitting 1. Measuring Stop the machine on a level place, lower the work equipment to the ground, and set the parking brake lever and safety lock lever in the LOCK position.
Measuring unload pressure 1 Remove the main control valve cover. Measuring work equipment oil pressure and HSS oil pressure 1 Remove the main control valve cover. HSS oil pressure i Start the engine, set the parking brake lever in the free position, and press the brake pedal. Since the steering circuit will be relieved, keep pressing the brake pedal securely and keep your right foot on the decelerator pedal for safety until the work is finished.
When the steering circuit is relieved, measure the oil pressure. Work equipment oil pressure: Work equipment oil pressure i Start the engine and set the safety lock lever in the free position. When each cylinder is relieved at the stroke end and measure the oil pressure.
Adjusting 1 LS pressure Load sensing pressure of work equipment Loosen locknut 4 of work equipment LS valve 3 and rotate adjustment screw 5 to adjust the LS pressure. Run the engine at high idling and set the blade lever and ripper lever in neutral and measure the oil pressure.
Remove the main control valve cover. Disconnect hose 1. After finishing measurement, remove the measuring instrument and return the removed parts. Adjusting a The self-pressure reducing valve cannot be adjusted.
Install oil pressure pickup adapter J2 and connect the disconnected hose again. Install nipple [1] of hydraulic tester J1 and connect oil pressure gauge [2]. Start the engine and set the safety lock lever in the FREE position. Run the engine at high idling and operate the control lever of the circuit to be measured and measure the oil pressure. Remove boot 1. Loosen locknut 2 and turn disc 3 to adjust the play. Fix disc 3 and tighten locknut 2. Install boot 1. Set the cylinders to be tested in the following positions and stop the engine.
Extend the cylinder to be tested with the corresponding lever and check its movement. Since the volume on the head side is less than that on the bottom side by the volume of the rod, the pressure in the head side is increased by the oil flowing in from the bottom side.
As a result, the pressure is unbalanced and the lowering speed is increased. Run the engine at low idling for about 5 minutes. Retract the cylinder to be measured to the stroke end and set the machine in the measuring position.
Running the engine at low idling, extend and retract the cylinder to be bled 4 — 5 times. Running the engine at high idling and carry out the operation in 2. Running the engine at low idling, move the cylinder to the stroke end to relieve the oil.
Disconnect hose on the cylinder bottom side and block the hose side with a plug. Take care not to disconnect the hose on the head side. Run the engine at high idling and apply the relief pressure to the cylinder head side. After 30 second, measure leakage in 1 minute. Run the engine at low idling and lower the blade and ripper to the ground without relieving each hydraulic cylinder. Set the safety lock lever in the FREE position and operate the blade lever and ripper lever forward, backward, to the right, and to the left.
Run the engine at low idling for about 5 seconds, and then stop it. Turn the starting switch OFF and quickly operate the blade lever and ripper lever forward, backward, to the right, and to the left. Repeat steps 2 and 3 by 2 — 3 times. Loosen the hydraulic tank cap gradually to release the residual pressure in the tank. Apply cloths to the joint of the cylinder piping and loosen the sleeve nut gradually to release the residual pressure, while shaking the hose slowly.
Adjust dimension a between pins of rod 1. Connect rod 1 to safety lock lever 2 and PPC lock valve 3. Run the engine at high idling and low idling and measure the fan motor speed. Be sure to close the radiator mask before starting the engine. Do not start the engine with the radiator mask open. Open the radiator mask. Remove hydraulic oil cooler 1 and fan guard 2 , and then return the hydraulic oil cooler.
Stick 1 sheet of reflecting tape [1] to fan 3. Set probe [2] of multitachometer [4] to stand [3], matching it to reflecting tape [1], then connect it to multitachometer [4].
Take care that the probe will not interfere with the fan. Close the radiator mask, run the engine, and set the monitor panel in the adjustment mode. Run the engine and set the monitor panel in the adjustment mode. Run the engine at high idling and measure the fan circuit pressure. Disconnect fan motor drive circuit hose 1 , install oil pressure pickup adapter P2, and connect hose 1 again.
Install nipple [1] of hydraulic tester P1 and connect oil pressure gauge [2]. D85EX Serial No. Remove 4 mounting bolts 2 and lower cooler 1 , leaving the hoses connected to the cooler as they are.
At this time, fix the cooler with wires to prevent it from moving while the circuit pressure is measured. Disconnect fan motor drive circuit hose 3 , install hydraulic adapter P2, and connect hose 3.
Remove the floor inspection cover R. Loosen air bleeder 1 and leave it for 15 minutes. After 15 minutes, run the engine at low idling. After oil flows out of air bleeder 1 , tighten air bleeder 1. Adjusting shims for assembly 1 Adjust the shim of center 1.
Note: Adjust the shim so that the play of the ball in the axial direction will be less than 1mm and the ball can rotate smoothly. Adjusting blade tilt distance 1 Adjust dimension c of brace 3 with the handle.
Pass the other end of the hose through the bolt hole and take it out of inspection cover 2 on the left side of the cab. Check of searing performance 1 Close the all openings of the cab. If there is any fault, repair it.
Check both sides, 2 pieces on each. Normal: When the door is closed, the damper rubber comes in contact lightly. Abnormal: When the door is closed, the damper rubber does not come in contact or comes in contact so strongly that adhesive tape is removed.
If the door is not locked and unlocked smoothly If the knob is heavy , perform the adjustment procedure from the first. Accordingly, apply grease sufficiently. Upper display section Gear speed display section 2. Lower display section Multi-information section. Normal function and special functions of monitor panel EMMS The monitor panel EMMS has the normal function and special functions and displays information of various types at the gear speed display section at its center and the multi-information section.
Some items are displayed automatically according to the internal setting of the monitor panel and the others are displayed according to the operation of the switches.
Normal function: Operation mode With this function, the operator can display and change the items displayed normally. Special function 1: Service mode With this function, a serviceman can display and change the displayed items with special switches for testing, adjusting, and troubleshooting.
Flow of modes and functions Operator mode Normal display Default. Operation and display in operator mode Outline a In this section, only the outline of the operation mode is described. For the details of the contents and operation method of each function and mode, see Operation Manual.
Normal display mode Default The monitor panel displays the following information normally. Pm clinic auxiliary mode 2-PM CLINIC MODE In this mode, the condition of the machine is displayed on multi-information section 2 as an auxiliary function of the periodic diagnoses such as the Pm clinic, even if any measuring instrument is not connected.
When the user or the operator needs to be notified of the error code of each fault, this mode is applied. To finish displaying, turn the buzzer cancel switch to the [ ] position. Action code display function If a fault to be notified to the operator occurs during work, an action code and a phone No.
The display shown at right is an example. The form of the displayed phone No. Even if an action code is not displayed, a fault may have occurred. You must take care, however. Operation and display in service mode Method of changing to service mode a When using the service mode, change the screen by the following special operation. Fleetwood Mac Michael Cooper Jacque D Manuals are as advertised, and if there is a problem, they will correct it immediately.
Nikistratos Kanavas Darren Milke Win Thu Stone Hill River Farms Mike Ardz New Zealand Jan-Olof Hansson Big Al Paul Garrison American Made Alex Jensen Blacky Dog Great site, ordered the wrong one, bought the correct one. They issued refund for my mistake. Dale Bruns The item is that i want but the booklet fastener is not strong. Now i set up another device. Serial NO. This edition of service manual for Komatsu D85EXR Bulldozer was primarily published to be used by mechanical technicians who are already familiar with all service procedures relating to BRP products.
This manual covers the repair and overhaul of Komatsu D85EXR Bulldozer cars and assumes that the technician is fully conversant with general automobile practices.
The repair procedures outlined in this manual emphasize the special aspects of the product. This will enable you to build and maintain a reputation of quality service. For repairs of proprietary components the instructions of the respective component manufacturers are included in this manual.
The purpose behind incorporating these instructions in this manual is to enable technicians to understand their functions properly and thus judge the performance of the car as a whole.
Page 5. Page 6. Page 7. Page 8. Page 9. Page This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics.
Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use. Yamaha Motor This product utilizes batteries or an external power supply adapter.
NOT connect this product to any power supply or adapter other than one described in the manual, on the name plate, or specifically recom- mended by Yamaha.
Model No. Serial No.
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