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Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Crawler Bulldozer Shop Manual 60001 and up – DOWNLOAD
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Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Crawler Bulldozer Shop Manual
MACHINE MODEL SERIAL NUMBER
D65E-12 60001 and up
D65P-12 60001 and up
D65EX-12 60001 and up
D65PX-12 60001 and up
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Description
Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D65E-12, D65P-12, D65EX-12, D65PX-12
Serial Number: 60001 and up
Book Code: SEBM001923
Language: English
Pages: 1262
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Crawler Bulldozer Shop Manual
FOREWORD:
GENERAL:
This shop 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 shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Crawler Bulldozer Shop Manual
COVER ............................................................................................................ 1 CONTENTS.......................................................................................................... 2 01 GENERAL........................................................................................................ 29 GENERAL ASSEMBLY DRAWING...................................................................................... 30 SPECIFICATIONS................................................................................................ 34 WEIGHT TABLE.................................................................................................. 50 TABLE OF FUEL, COOLANT AND LUBRICANTS......................................................................... 56 10 STRUCTURE AND FUNCTION......................................................................................... 60 RADIATOR,OIL COOLER........................................................................................... 61 ENGINE CONTROL................................................................................................ 63 POWER TRAIN SYSTEM............................................................................................ 66 POWER TRAIN SKELETON.......................................................................................... 67 POWER TRAIN UNIT.............................................................................................. 71 POWER TRAIN HYDRAULIC PIPING DIAGRAM.......................................................................... 73 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM......................................................................... 77 POWER TRAIN HYDRAULIC SYSTEM DIAGRAM.......................................................................... 78 DAMPER,UNIVERSAL JOINT........................................................................................ 82 TORQUE CONVERTER AND PTO...................................................................................... 84 TRANSMISSION CONTROL.......................................................................................... 86 TRANSMISSION.................................................................................................. 89 TRANSMISSION CONTROL VALVE.................................................................................... 98 MAIN RELIEF VALVE............................................................................................. 107 LUBRICATION RELIEF VALVE...................................................................................... 109 STEERING,BRAKE CONTROL........................................................................................ 110 BEVEL GEAR SHAFT, STEERING CLUTCH,STEERING BRAKE (D65E,P-12).................................................. 112 STEERING CONTROL VALVE (D65E,P-12)............................................................................ 125 STEERING BRAKE VALVE (D65E,P-12).............................................................................. 132 REDUCING VALVE................................................................................................ 136 STEERING AND BRAKE CONTROL (D65EX,PX-12)...................................................................... 138 BEVEL GEAR SHAFT, HSS STEERING AND BRAKE (D65EX,PX-12)........................................................ 141 BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)............................................................... 162 SCAVENGING PUMP STRAINER...................................................................................... 166 POWER TRAIN OIL STRAINER...................................................................................... 167 POWER TRAIN OIL FILTER........................................................................................ 168 FINAL DRIVE................................................................................................... 169 MAIN FRAME.................................................................................................... 175 TRACK FRAME................................................................................................... 176 RECOIL SPRING................................................................................................. 178 SUSPENSION.................................................................................................... 182 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM....................................................................... 186 ANGLEDOZER................................................................................................ 186 STRAIGHT TILTDOZER........................................................................................ 188 POWER PITCH DOZER......................................................................................... 190 RIPPER.................................................................................................... 192 PPC CONTROL PIPING DIAGRAM.................................................................................... 193 WORK EQUIPMENT CONTROL........................................................................................ 198 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................... 200 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....................................................................... 201 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM......................................................... 208 STEERING AND WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.......................................................... 209 HYDRAULIC TANK AND FILTER..................................................................................... 216 HYDRAULIC,HSS PUMP (D65EX,PX-12).............................................................................. 220 PPC VALVE (FOR STEERING) (D65EX,PX-12)........................................................................ 235 PPC VALVE (FOR STEERING) (D65E,P-12).......................................................................... 242 PPC VALVE (FOR BLADE LIFT, TILT AND RIPPER)................................................................... 246 PPC CHARGE VALVE.............................................................................................. 259 PPC LOCK VALVE................................................................................................ 261 MAIN CONTROL VALVE (2-SPOOL VALVE) (D65E,P-12)................................................................ 262 MAIN CONTROL VALVE (2-SPOOL VALVE) (D65EX,PX-12).............................................................. 300 POWER PITCH SELECTOR VALVE.................................................................................... 352 HSS MOTOR..................................................................................................... 355 OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT......................................................... 360 SUCTION VALVE................................................................................................. 368 PISTON VALVE.................................................................................................. 372 WORK EQUIPMENT................................................................................................ 373 ELECTRICAL CIRCUIT DIAGRAM.................................................................................... 377 ENGINE CONTROL................................................................................................ 389 MACHINE MONITOR SYSTEM........................................................................................ 390 SENSORS....................................................................................................... 394 20 TESTING AND ADJUSTING.......................................................................................... 397 STANDARD VALUE TABLE FOR ENGINE............................................................................... 398 STANDARD VALUE TABLE FOR CHASSIS.............................................................................. 406 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.................................................................... 435 TOOL LIST FOR TESTING AND ADJUSTING........................................................................... 438 ADJUSTING VALVE CLEARANCE..................................................................................... 440 MEASURING COMPRESSION PRESSURE................................................................................ 441 MEASURING BLOWBY.............................................................................................. 442 ADJUSTING FULE INJECTION TIMING............................................................................... 443 MEASURING EXHAUST COLOR....................................................................................... 445 MEASURING BOOST PRESSURE...................................................................................... 446 MEASURING EXHAUST TEMPERATURE (D65P,EX,PX-12)................................................................. 447 MEASURING ENGINE OIL PRESSURE................................................................................. 448 MEASURING ENGINE SPEED........................................................................................ 448 TESTING FAN BELT TENSION...................................................................................... 449 MEASURING SPEED AT TORQUE CONVERTER STALL..................................................................... 450 ADJUSTING FULE CONTROL LINKAGE................................................................................ 451 ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE (D65E,P).............. 457 ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE (D65EX,PX)............................... 464 ADJUSTING BRAKE PEDAL LINKAGE................................................................................. 470 D65E,P.................................................................................................... 470 D65EX,PX.................................................................................................. 472 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE...................................................................... 473 ADJUSTING STRAIGHT TILTDOZER.................................................................................. 475 ADJUSTING PPC VALVE........................................................................................... 477 MEASURING POWER TRAIN OIL PRESSURE............................................................................ 478 D65E,P.................................................................................................... 478 D65EX,PX.................................................................................................. 485 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE (D65E,P).............................................. 492 TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE (D65EX,PX).................................. 493 TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE................................................................ 495 MEASURING OUTPUT PRESSURE OF PPC VALVE........................................................................ 497 MEASURING OIL LEAKAGE FROM HSS MOTOR (D65EX,PX)............................................................... 499 MEASURING LEAKAGE INSIDE CYLINDER............................................................................. 499 BLEEDING AIR FROM HYDRAULIC CYLINDER.......................................................................... 500 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT........................................................... 500 PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE....................................................... 501 PROCEDURE FOR TESTING SENSORS................................................................................. 502 TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATORS CAB DOOR........................... 504 TROUBLESHOOTING............................................................................................... 507 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................... 508 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 509 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................... 510 CHECKS BEFORE TROUBLESHOOTING............................................................................. 518 METHOD OF USING MATRIX TROUBLESHOOTING CHART.............................................................. 519 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................... 523 TYPE OF CONNECTOR AND POSITION OF INSTALLATION............................................................ 525 CONNECTOR POSITION DRAWING................................................................................ 530 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................ 532 ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM................................................................ 555 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................ 559 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................... 560 S-2 ENGING DOES NOT START............................................................................. 561 (1) ENGINE DOES NOT TURN.......................................................................... 561 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)........................ 562 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...................... 563 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).............................................. 564 S-4 ENGINE STOPS DURING OPERATIONS.................................................................... 565 S-5 ENGINE DOES NO ROTATE SMOOTHLY (HUNTING).......................................................... 566 S-6 ENGINE LACKS OUTPUT (NO POWER).................................................................... 567 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...................................................... 568 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)............................................. 569 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................. 570 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................... 571 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.......................... 572 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................... 573 S-13 OIL LEVEL RISES.................................................................................. 574 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................. 575 S-15 ABNORMAL NOISE IS MADE........................................................................... 576 S-16 VIBRATION IS EXCESSIVE........................................................................... 577 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)................................................... 578 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC,MECHANICAL SYSTEMS)...................................... 579 H-1 BRAKE DOES NOT WORK............................................................................... 580 H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE) (D65E,P-12)................................. 581 H-3 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING (D65EX,PX-12)..................... 583 H-4 OVERRUNS WHEN TURNING (D65E,P-12)................................................................. 585 H-5 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING LEVER IS OPERATED) (D65E,P-12)...................... 586 H-6 EXCESSIVE TIME LAG................................................................................ 588 H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)..................................... 588 H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)................. 589 1) D65E,P-12...................................................................................... 589 2) D65EX,PX-12.................................................................................... 591 H-9 MACHINE DOES NOT MOVE IN ANY SPEED RANGE.......................................................... 593 1) D65E,P-12...................................................................................... 593 2) D65EX,PX-12.................................................................................... 595 H-10 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH....................................................... 597 H-11 DRAWBAR PULL IS WEEK,TRAVEL SPEED IS SLOW........................................................ 599 1) D65E,P-12...................................................................................... 599 2) D65EX,PX-12.................................................................................... 601 H-13 ABNORMAL NOISES IS GENERATED FROM AROUND HYDRAULIC PUMP OR HYDRAULIC,HSS PUMP.................... 602 H-14 SPEED OF ALL WORK EQUIPMENT IS SLOW (D65E,P-12).................................................. 603 H-15 NO WORK EQUIPMENT MOVES (D65E,P-12).............................................................. 605 H-16 ALL WORK EQUIPMENT LACKS POWER (D65E,P-12)....................................................... 605 H-17 TURNING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW (D65EX,PX-12).............................. 606 H-18 MACHINE CANNOT TURN AND NO WORK EQUIPMENT MOVES (D65EX,PX-12).................................... 608 H-19 TURNING AND ALL WORK EQUIPMENT LACKS POWER (D65EX,PX-12)......................................... 608 H-20 BLADE LIFTING SPEED IS SLOW OR LACKS POWER....................................................... 609 1) D65E,P-12...................................................................................... 609 2) D65EX,PX-12.................................................................................... 609 H-21 BLADE TILT SPEED IS SLOW OR LACKS POWER.......................................................... 610 1) D65E,P-12...................................................................................... 610 2) D65EX,PX-12.................................................................................... 610 H-22 HYDRAULIC DRIFT OF BLADE LIFY IS EXCESSIVE....................................................... 611 H-23 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE....................................................... 611 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................................. 612 TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)................................................. 613 E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO 0N................................ 614 E-2 LAMP DO NOT LIGHT UP.............................................................................. 620 a) FRONT LAMPS.................................................................................... 620 b) REAR LAMPS..................................................................................... 621 E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO ....................... 624 E-5 WIPER DOES NOT WORK............................................................................... 630 E-6 NO WASHER FLUID IS SPRAYED OUT.................................................................... 632 E-7 AIR CONDITION HAS NOT EFFECT...................................................................... 634 a) NO AIR COMES OUT............................................................................... 634 b) DOES NOT BECOME COOL .......................................................................... 638 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)........................................................ 642 TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)............................................ 643 M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON......................... 644 M-2 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT............. 644 M-3 PREHEATING DISPLAY IS ABNORMAL.................................................................... 645 a) PREHEATING MONITOR DOES NOT LIGHT UP........................................................... 645 b) PREHEATING MONITOR DOES NOT GO OUT............................................................. 645 M-4 CAUTION ITEMS LIGHT UP OR FLASH................................................................... 651 a) (CHARGE) LIGHTS UP OR FLASHES.................................................................. 651 b) WHEN STARTING SWITCH AT ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES.... 652 c) (COOLANT TEMPERATURE) FLASHES.................................................................. 653 d) (POWER TRAIN OIL TEMPERATURE) FLASHES.......................................................... 655 M-5 BUZZER IS ABNORMAL................................................................................ 657 a) CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND................................................ 657 b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS................................................... 657 M-6 WARNING LAMP IS ABNORMAL.......................................................................... 658 a) CAUTION ITEM FLASHING BUT LAMP DOES NOT FLASH.................................................. 658 b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES..................................................... 658 M-7 GAUGE IS ABNORMAL................................................................................. 659 a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE................................................ 659 b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE............................................... 660 c) ABNORMALITY IN FUEL LEVEL GAUGE................................................................ 661 M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED............................................... 665 M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)................................. 666 30 DISASSEMBLY AND ASSEMBLY....................................................................................... 668 METHOD OF USING MANUAL........................................................................................ 671 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................... 672 SPECIAL TOOL LIST............................................................................................. 674 SPECIAL TOOL SKETCH........................................................................................... 680 STARTING MOTOR................................................................................................ 682 REMOVAL................................................................................................... 682 INSTALLATION.............................................................................................. 682 ALTERNATOR ASSEMBLY........................................................................................... 683 REMOVAL................................................................................................... 683 INSTALLATION.............................................................................................. 683 ENGINE OIL COOLER CORE........................................................................................ 685 REMOVAL................................................................................................... 685 INSTALLATION.............................................................................................. 685 FUEL INJECTION PUMP ASSEMBLY.................................................................................. 686 REMOVAL................................................................................................... 686 INSTALLATION.............................................................................................. 687 WATER PUMP ASSEMBLY........................................................................................... 688 REMOVAL................................................................................................... 688 INSTALLATION.............................................................................................. 688 TURBOCHARGER ASSEMBLY......................................................................................... 690 REMOVAL................................................................................................... 690 INSTALLATION.............................................................................................. 690 NOZZLE HOLDER ASSEMBLY (D65P,EX,PX)........................................................................... 691 REMOVAL................................................................................................... 691 INSTALLATION.............................................................................................. 691 NOZZLE HOLDER ASSEMBLY (D65E)................................................................................. 692 REMOVAL................................................................................................... 692 INSTALLATION.............................................................................................. 692 THERMOSTAT ASSEMBLY........................................................................................... 693 REMOVAL................................................................................................... 693 INSTALLATION.............................................................................................. 693 CYLINDER HEAD ASSEMBLY (D65P,EX,PX)........................................................................... 695 REMOVAL................................................................................................... 695 INSTALLATION.............................................................................................. 699 CYLINDER HEAD ASSEMBLY (D65E)................................................................................. 707 REMOVAL................................................................................................... 707 INSTALLATION.............................................................................................. 710 ENGINE FRONT SEAL............................................................................................. 717 REMOVAL................................................................................................... 717 INSTALLATION.............................................................................................. 718 ENGINE REAR SEAL.............................................................................................. 719 REMOVAL................................................................................................... 719 INSTALLATION.............................................................................................. 720 AIR CONDITIONER COMPRESSOR ASSEMBLY........................................................................... 723 REMOVAL................................................................................................... 723 INSTALLATION.............................................................................................. 723 AIR CONDITIONER CONDENSER ASSEMBLY............................................................................ 724 REMOVAL................................................................................................... 724 INSTALLATION.............................................................................................. 724 FUEL TANK ASSEMBLY............................................................................................ 725 REMOVAL................................................................................................... 725 INSTALLATION.............................................................................................. 726 RADIATOR ASSEMBLY............................................................................................. 731 REMOVAL................................................................................................... 731 INSTALLATION.............................................................................................. 733 ENGINE ASSEMBLY (CAB SPECIFICATION)........................................................................... 734 REMOVAL................................................................................................... 734 INSTALLATION.............................................................................................. 737 ENGINE ASSEMBLY (CANOPY SPECIFICATION)........................................................................ 742 REMOVAL................................................................................................... 742 INSTALLATION.............................................................................................. 744 DAMPER ASSEMBLY............................................................................................... 748 REMOVAL................................................................................................... 748 INSTALLATION.............................................................................................. 750 POWER TRAIN UNIT ASSEMBLY (D65E,P)............................................................................ 752 REMOVAL................................................................................................... 752 INSTALLATION.............................................................................................. 757 POWER TRAIN UNIT ASSEMBLY (D65EX,PX).......................................................................... 758 REMOVAL................................................................................................... 758 INSTALLATION.............................................................................................. 763 POWER TRAIN UNIT (D65E,P)..................................................................................... 764 SEPARATION................................................................................................ 764 CONNECTION................................................................................................ 767 POWER TRAIN UNIT (D65EX,PX)................................................................................... 768 SEPARATION................................................................................................ 768 CONNECTION................................................................................................ 771 TORQUE CONVERTER ASSEMBLY..................................................................................... 772 DISASSEMBLY............................................................................................... 772 ASSEMBLY.................................................................................................. 774 PTO ASSEMBLY.................................................................................................. 777 DISASSEMBLY............................................................................................... 777 ASSEMBLY.................................................................................................. 780 TORQFLOW TRANSMISSION ASSEMBLY................................................................................ 784 DISASSEMBLY............................................................................................... 784 ASSEMBLY.................................................................................................. 803 STEERING CASE ASSEMBLY (D65E,P)............................................................................... 831 DISASSEMBLY............................................................................................... 831 ASSEMBLY.................................................................................................. 844 HSS ASSEMBLY (D65EX,PX)....................................................................................... 866 DISASSEMBLY............................................................................................... 866 ASSEMBLY.................................................................................................. 887 TORQUE CONVERTER VALVE ASSEMBLY............................................................................... 911 REMOVAL................................................................................................... 911 INSTALLATION.............................................................................................. 911 DISASSEMBLY............................................................................................... 912 ASSEMBLY.................................................................................................. 912 TRANSMISSION CONTROL VALVE ASSEMBLY........................................................................... 913 REMOVAL................................................................................................... 913 INSTALLATION.............................................................................................. 913 DISASSEMBLY............................................................................................... 915 ASSEMBLY.................................................................................................. 915 STEERING CONTROL VALVE ASSEMBLY (D65E,P)...................................................................... 919 REMOVAL................................................................................................... 919 INSTALLATION.............................................................................................. 919 DISASSEMBLY............................................................................................... 920 ASSEMBLY.................................................................................................. 922 BRAKE VALVE ASSEMBLY (D65EX,PX)............................................................................... 924 REMOVAL................................................................................................... 924 INSTALLATION.............................................................................................. 924 DISASSEMBLY............................................................................................... 925 ASSEMBLY.................................................................................................. 926 REDUCING VALVE ASSEMBLY (D65E,P).............................................................................. 927 REMOVAL................................................................................................... 927 INSTALLATION.............................................................................................. 927 DISASSEMBLY............................................................................................... 928 ASSEMBLY.................................................................................................. 928 HSS MOTOR ASSEMBLY (D65EX,PX)................................................................................. 929 REMOVAL................................................................................................... 929 INSTALLATION.............................................................................................. 929 DISASSEMBLY............................................................................................... 930 ASSEMBLY.................................................................................................. 934 SCAVENGING PUMP ASSEMBLY...................................................................................... 941 REMOVAL................................................................................................... 941 INSTALLATION.............................................................................................. 941 POWER TRAIN PUMP ASSEMBLY..................................................................................... 942 REMOVAL................................................................................................... 942 INSTALLATION.............................................................................................. 942 FINAL DRIVE ASSEMBLY.......................................................................................... 943 REMOVAL................................................................................................... 943 INSTALLATION.............................................................................................. 944 DISASSEMBLY............................................................................................... 947 ASSEMBLY.................................................................................................. 952 TRACK FRAME ASSEMBLY.......................................................................................... 971 REMOVAL................................................................................................... 971 INSTALLATION.............................................................................................. 972 RECOIL SPRING ASSENBLY........................................................................................ 973 REMOVAL................................................................................................... 973 INSTALLATION.............................................................................................. 973 DISASSEMBLY............................................................................................... 975 ASSEMBLY.................................................................................................. 977 IDLER ASSEMBLY................................................................................................ 981 REMOVAL................................................................................................... 981 INSTALLATION.............................................................................................. 981 DISASSEMBLY............................................................................................... 983 ASSEMBLY.................................................................................................. 984 TRACK ROLLER ASSEMBLY......................................................................................... 989 REMOVAL................................................................................................... 989 INSTALLATION.............................................................................................. 989 DISASSEMBLY............................................................................................... 990 ASSEMBLY.................................................................................................. 991 CARRIER ROLLER ASSEMBLY (D65P,PX)............................................................................. 993 REMOVAL................................................................................................... 993 INSTALLATION.............................................................................................. 993 CARRIER ROLLER ASSEMBLY (D65E,EX)............................................................................. 994 REMOVAL................................................................................................... 994 INSTALLATION.............................................................................................. 994 DISASSEMBLY (D65E,P,EX,PX)................................................................................ 995 ASSEMBLY (D65E,P,EX,PX)................................................................................... 996 TRACK SHOE.................................................................................................... 997 CHECKING BEFORE REMOVAL................................................................................... 997 REMOVAL (NORMAL).......................................................................................... 997 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME).................................................... 998 INSTALLATION.............................................................................................. 999 OVERALL DISASSEMBLY.......................................................................................1003 OVERALL ASSEMBLY..........................................................................................1008 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS..........................................................1022 FIELD DISASSEMBLY OF ONE LINK.............................................................................1023 FIELD ASSEMBLY OF ONE LINK................................................................................1024 PIVOT SHAFT ASSEMBLY..........................................................................................1030 REMOVAL...................................................................................................1030 INSTALLATION..............................................................................................1030 EQUALIZER BAR ASSEMBLY........................................................................................1031 REMOVAL...................................................................................................1031 INSTALLATION..............................................................................................1032 EQUALIZER SIDE BUSHING........................................................................................1033 REMOVAL...................................................................................................1033 INSTALLATION..............................................................................................1033 SEGMENT TEETH.................................................................................................1034 REMOVAL...................................................................................................1034 INSTALLATION..............................................................................................1034 WORK EQUIPMENT PUMP ASSEMBLY (D65E,P).........................................................................1035 REMOVAL...................................................................................................1035 INSTALLATION..............................................................................................1035 HSS, WORK EQUIPMENT PUMP ASSEMBLY (D65EX,PX)..................................................................1036 REMOVAL...................................................................................................1036 INSTALLATION..............................................................................................1036 DISASSEMBLY...............................................................................................1037 ASSEMBLY..................................................................................................1042 PPC PUMP ASSEMBLY.............................................................................................1051 REMOVAL...................................................................................................1051 INSTALLATION..............................................................................................1051 MAIN CONTROL VALVE ASSEMBLY...................................................................................1052 REMOVAL...................................................................................................1052 INSTALLATION..............................................................................................1052 DISASSEMBLY (3-SPOOL VALVE)...............................................................................1055 ASSEMBLY..................................................................................................1057 MAIN RELIEF VALVE.............................................................................................1063 REMOVAL...................................................................................................1063 INSTALLATION..............................................................................................1063 PPC VALVE ASSEMBLY............................................................................................1064 REMOVAL (FOR WORK EQUIPMENT)..............................................................................1064 INSTALLATION (FOR WORK EQUIPMENT).........................................................................1064 REMOVAL (D65EX,PX,FOR STEERING)...........................................................................1066 INSTALLATION (D65EX,PX,FOR STEERING)......................................................................1067 DISASSEMBLY (FOR WORK EQUIPMENT)..........................................................................1070 ASSEMBLY (FOR WORK EQUIPMENT).............................................................................1071 DISASSEMBLY (D65EX,PX,FOR STEERING) ......................................................................1072 ASSEMBLY (D65EX,PX,FOR STEERING)..........................................................................1073 PPC CHARGE RELIEF VALVE ASSEMBLY..............................................................................1074 REMOVAL...................................................................................................1074 INSTALLATION..............................................................................................1074 DISASSEMBLY...............................................................................................1075 ASSEMBLY..................................................................................................1075 SUCTION VALVE ASSEMBLY........................................................................................1076 REMOVAL...................................................................................................1076 INSTALLATION..............................................................................................1076 BLADE LIFT CYLINDER ASSEMBLY..................................................................................1077 REMOVAL...................................................................................................1077 INSTALLATION..............................................................................................1077 BLADE TILT CYLINDER ASSEMBLY..................................................................................1078 REMOVAL...................................................................................................1078 INSTALLATION..............................................................................................1078 HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER).................................................1079 DISASSEMBLY...............................................................................................1079 ASSEMBLY..................................................................................................1081 WORK EQUIPMENT ASSEMBLY.......................................................................................1084 REMOVAL...................................................................................................1084 INSTALLATION..............................................................................................1085 DISASSEMBLY...............................................................................................1086 ASSEMBLY..................................................................................................1088 RIPPER VALVE ASSEMBLY (OPT.)..................................................................................1090 DISASSEMBLY...............................................................................................1090 ASSEMBLY..................................................................................................1091 ROPS GUARD....................................................................................................1092 REMOVAL...................................................................................................1092 INSTALLATION..............................................................................................1092 OPERATOR'S CAB ASSEMBLY.......................................................................................1093 REMOVAL...................................................................................................1093 INSTALLATION..............................................................................................1094 CANOPY ASSEMBLY...............................................................................................1095 REMOVAL...................................................................................................1095 INSTALLATION..............................................................................................1095 DASHBOARD ASSEMBLY............................................................................................1096 REMOVAL...................................................................................................1096 INSTALLATION..............................................................................................1096 MONITOR ASSEMBLY..............................................................................................1097 REMOVAL...................................................................................................1097 INSTALLATION..............................................................................................1097 FLOOR FRAME ASSEMBLY (D65E,P).................................................................................1098 REMOVAL...................................................................................................1098 INSTALLATION..............................................................................................1101 FLOOR FRAME ASSEMBLY (D65EX,PX)...............................................................................1106 REMOVAL...................................................................................................1106 INSTALLATION..............................................................................................1109 40 MAINTENANCE STANDARD...........................................................................................1114 ENGINE MOUNT..................................................................................................1115 POWER TRAIN UNIT MOUNT........................................................................................1116 DAMPER, UNIVERSAL JOINT.......................................................................................1117 TORQUE CONVERTER, PTO.........................................................................................1118 TRANSMISSION..................................................................................................1120 TRANSMISSION CONTROL VALVE....................................................................................1124 MAIN RELIEF VALVE.............................................................................................1127 BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E,P-12).................................................1128 BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)......................................................1132 BEVEL GEAR SHAFT, HSS STEERING BRAKE (2/2) (D65EX,PX-12)......................................................1134 BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)......................................................1136 STEERING CONTROL VALVE (D65E,P-12)............................................................................1139 BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)...............................................................1140 POWER TRAIN, LUBRICATION PUMP.................................................................................1141 PPC PUMP......................................................................................................1142 PPC VALVE.....................................................................................................1144 FOR STEERING (D65EX,PX-12)................................................................................1144 FOR BLADE LIFT, BLADE TILT, RIPPER LIFT (D65E,P-12,D65EX,PX-12)...........................................1145 PPC CHARGE VALVE..............................................................................................1149 FINAL DRIVE...................................................................................................1150 HULL FRAME....................................................................................................1158 TRACK FRAME, RECOIL SPRING....................................................................................1160 IDLER.........................................................................................................1162 TRACK ROLLER..................................................................................................1165 CARRIER ROLLER................................................................................................1167 SPROCKET TOOTH PROFILE........................................................................................1168 TRACK SHOE (DRY TYPE).........................................................................................1169 TRACK SHOE (LUBRICATION TYPE).................................................................................1171 SUSPENSION....................................................................................................1173 HYDRAULIC PUMP (D65E,P-12)....................................................................................1177 HYDRAULIC, HSS PUMP (D65EX,PX-12).............................................................................1179 HSS MOTOR (D65EX,PX-12).......................................................................................1180 MAIN CONTROL VALVE............................................................................................1181 2+1-SPOOL VALVE (D65E,P-12)...............................................................................1181 3+1-SPOOL VALVE (D65EX,PX-12).............................................................................1191 WORK EQUIPMENT CYLINDER.......................................................................................1201 WORK EQUIPMENT................................................................................................1203 CUTTING EDGE, END BIT.........................................................................................1209 RIPPER........................................................................................................1210 90 OTHERS.........................................................................................................1211 SPECIFICATIONS................................................................................................1212 SPECIFICATION DRAWING.....................................................................................1212 SPECIFICATIONS............................................................................................1213 WEIGHT TABLE..............................................................................................1219 TABLE OF FUEL, COOLANT AND LUBRICANTS.....................................................................1222 STRUCTURE AND FUNCTION........................................................................................1223 REAR GUARD................................................................................................1223 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM...................................................................1224 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....................................................1225 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..................................................................1227 WORK EQUIPMENT CONTROL....................................................................................1228 MAIN CONTROL VALVE........................................................................................1229 TRIMMING DOZER............................................................................................1233 MAINTENANCE STANDARD..........................................................................................1234 MAIN CONTROL VALVE........................................................................................1234 WORK EQUIPMENT CYLINDER...................................................................................1243 TRIMMING DOZER............................................................................................1245 D65EX,PX-12 (FOR KA SPEC.)....................................................................................1246 STRUCTURE AND FUNCTION........................................................................................1247 ENGINE CONTROL............................................................................................1247 TRANSMISSION CONTROL......................................................................................1248 STEERING AND BRAKE CONTROL................................................................................1249 PPC CONTROL PIPING DIAGRAM................................................................................1250 TESTING AND ADJUSTING.........................................................................................1251 STANDARD VALUE TABLE FOR CHASSIS..........................................................................1251 ADJUSTING FUEL CONTROL LINKAGE............................................................................1253 ADJUSTING LINKAGE OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER, AND PARKING BRAKE LEVER.....................1255 TROUBLESHOOTING...............................................................................................1257 CONNECTOR TYPES AND MOUNTING LOCATIONS....................................................................1257 CONNECTOR POSITION DRAWING................................................................................1258 ELECTRIC CIRCUIT DIAGRAM......................................................................................1260 ELECTRIC CIRCUIT DIAGRAM FOR CAB..........................................................................1260 CAB SPECIFICATION.........................................................................................1261 CANOPY SPECIFICATION......................................................................................1262
KOMATSU D65E-12, D65P-12, D65EX-12, D65PX-12 CRAWLER BULLDOZER SHOP MANUAL 60001 AND UP – DOWNLOAD:
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Rhys Emilio –
Thanks. Looks good.