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KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001922 – PDF DOWNLOAD
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KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001922 – PDF DOWNLOAD
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KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001922 – PDF DOWNLOAD
Language : English
Pages : 1228
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001922 – PDF DOWNLOAD
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......................................................................................... 58 RADIATOR,OIL COOLER........................................................................................... 59 ENGINE CONTROL................................................................................................ 61 POWER TRAIN SYSTEM............................................................................................ 64 POWER TRAIN SKELETON.......................................................................................... 65 POWER TRAIN UNIT.............................................................................................. 68 POWER TRAIN HYDRAULIC PIPING DIAGRAM.......................................................................... 70 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM......................................................................... 74 POWER TRAIN HYDRAULIC SYSTEM DIAGRAM.......................................................................... 75 DAMPER,UNIVERSAL JOINT........................................................................................ 79 TORQUE CONVERTER AND PTO...................................................................................... 81 TRANSMISSION CONTROL.......................................................................................... 83 TRANSMISSION.................................................................................................. 86 TRANSMISSION CONTROL VALVE.................................................................................... 95 MAIN RELIEF VALVE............................................................................................. 104 LUBRICATION RELIEF VALVE...................................................................................... 106 STEERING,BRAKE CONTROL........................................................................................ 107 BEVEL GEAR SHAFT, STEERING CLUTCH,STEERING BRAKE (D65E,P-12).................................................. 109 STEERING CONTROL VALVE (D65E,P-12)............................................................................ 122 STEERING BRAKE VALVE (D65E,P-12).............................................................................. 129 REDUCING VALVE................................................................................................ 133 STEERING AND BRAKE CONTROL (D65EX,PX-12)...................................................................... 135 BEVEL GEAR SHAFT, HSS STEERING AND BRAKE (D65EX,PX-12)........................................................ 138 BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)............................................................... 159 SCAVENGING PUMP STRAINER...................................................................................... 163 POWER TRAIN OIL STRAINER...................................................................................... 164 POWER TRAIN OIL FILTER........................................................................................ 165 FINAL DRIVE................................................................................................... 166 MAIN FRAME.................................................................................................... 169 TRACK FRAME................................................................................................... 170 RECOIL SPRING................................................................................................. 172 SUSPENSION.................................................................................................... 174 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM....................................................................... 178 ANGLEDOZER................................................................................................ 178 STRAIGHT TILTDOZER........................................................................................ 180 POWER PITCH DOZER......................................................................................... 182 RIPPER.................................................................................................... 184 PPC CONTROL PIPING DIAGRAM.................................................................................... 185 WORK EQUIPMENT CONTROL........................................................................................ 190 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................... 192 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....................................................................... 193 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM......................................................... 200 STEERING AND WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.......................................................... 201 HYDRAULIC TANK AND FILTER..................................................................................... 208 HYDRAULIC,HSS PUMP (D65EX,PX-12).............................................................................. 212 PPC VALVE (FOR STEERING) (D65EX,PX-12)........................................................................ 227 PPC VALVE (FOR STEERING) (D65E,P-12).......................................................................... 234 PPC VALVE (FOR BLADE LIFT, TILT AND RIPPER)................................................................... 238 PPC CHARGE VALVE.............................................................................................. 251 PPC LOCK VALVE................................................................................................ 253 MAIN CONTROL VALVE (2-SPOOL VALVE) (D65E,P-12)................................................................ 254 MAIN CONTROL VALVE (2-SPOOL VALVE) (D65EX,PX-12).............................................................. 292 POWER PITCH SELECTOR VALVE.................................................................................... 344 HSS MOTOR..................................................................................................... 347 OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT......................................................... 352 SUCTION VALVE................................................................................................. 360 PISTON VALVE.................................................................................................. 364 WORK EQUIPMENT................................................................................................ 365 ELECTRICAL CIRCUIT DIAGRAM.................................................................................... 369 ENGINE CONTROL................................................................................................ 381 MACHINE MONITOR SYSTEM........................................................................................ 382 SENSORS....................................................................................................... 386 20 TESTING AND ADJUSTING.......................................................................................... 389 STANDARD VALUE TABLE FOR ENGINE............................................................................... 390 STANDARD VALUE TABLE FOR CHASSIS.............................................................................. 398 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.................................................................... 427 TOOL LIST FOR TESTING AND ADJUSTING........................................................................... 430 ADJUSTING VALVE CLEARANCE..................................................................................... 432 MEASURING COMPRESSION PRESSURE................................................................................ 433 MEASURING BLOWBY.............................................................................................. 434 ADJUSTING FULE INJECTION TIMING............................................................................... 435 MEASURING EXHAUST COLOR....................................................................................... 437 MEASURING BOOST PRESSURE...................................................................................... 438 MEASURING EXHAUST TEMPERATURE (D65P,EX,PX-12)................................................................. 439 MEASURING ENGINE OIL PRESSURE................................................................................. 440 MEASURING ENGINE SPEED........................................................................................ 440 TESTING FAN BELT TENSION...................................................................................... 441 MEASURING SPEED AT TORQUE CONVERTER STALL..................................................................... 442 ADJUSTING FULE CONTROL LINKAGE................................................................................ 443 ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE (D65E,P).............. 449 ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE (D65EX,PX)............................... 456 ADJUSTING BRAKE PEDAL LINKAGE................................................................................. 462 D65E,P.................................................................................................... 462 D65EX,PX.................................................................................................. 464 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE...................................................................... 465 ADJUSTING STRAIGHT TILTDOZER.................................................................................. 467 ADJUSTING PPC VALVE........................................................................................... 469 MEASURING POWER TRAIN OIL PRESSURE............................................................................ 470 D65E,P.................................................................................................... 470 D65EX,PX.................................................................................................. 477 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE (D65E,P).............................................. 484 TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE (D65EX,PX).................................. 485 TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE................................................................ 487 MEASURING OUTPUT PRESSURE OF PPC VALVE........................................................................ 489 MEASURING OIL LEAKAGE FROM HSS MOTOR (D65EX,PX)............................................................... 491 MEASURING LEAKAGE INSIDE CYLINDER............................................................................. 491 BLEEDING AIR FROM HYDRAULIC CYLINDER.......................................................................... 492 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT........................................................... 492 PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE....................................................... 493 PROCEDURE FOR TESTING SENSORS................................................................................. 494 TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATORS CAB DOOR........................... 496 TROUBLESHOOTING............................................................................................... 499 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................... 500 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 501 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................... 502 CHECKS BEFORE TROUBLESHOOTING............................................................................. 510 METHOD OF USING MATRIX TROUBLESHOOTING CHART.............................................................. 511 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................... 515 TYPE OF CONNECTOR AND POSITION OF INSTALLATION............................................................ 517 CONNECTOR POSITION DRAWING................................................................................ 522 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................ 524 ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM................................................................ 547 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................ 551 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................... 552 S-2 ENGING DOES NOT START............................................................................. 553 (1) ENGINE DOES NOT TURN.......................................................................... 553 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)........................ 554 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...................... 555 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).............................................. 556 S-4 ENGINE STOPS DURING OPERATIONS.................................................................... 557 S-5 ENGINE DOES NO ROTATE SMOOTHLY (HUNTING).......................................................... 558 S-6 ENGINE LACKS OUTPUT (NO POWER).................................................................... 559 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...................................................... 560 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)............................................. 561 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................. 562 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................... 563 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.......................... 564 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................... 565 S-13 OIL LEVEL RISES.................................................................................. 566 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................. 567 S-15 ABNORMAL NOISE IS MADE........................................................................... 568 S-16 VIBRATION IS EXCESSIVE........................................................................... 569 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)................................................... 570 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC,MECHANICAL SYSTEMS)...................................... 571 H-1 BRAKE DOES NOT WORK............................................................................... 572 H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE) (D65E,P-12)................................. 573 H-3 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING (D65EX,PX-12)..................... 575 H-4 OVERRUNS WHEN TURNING (D65E,P-12)................................................................. 577 H-5 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING LEVER IS OPERATED) (D65E,P-12)...................... 578 H-6 EXCESSIVE TIME LAG................................................................................ 580 H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)..................................... 580 H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)................. 581 1) D65E,P-12...................................................................................... 581 2) D65EX,PX-12.................................................................................... 583 H-9 MACHINE DOES NOT MOVE IN ANY SPEED RANGE.......................................................... 585 1) D65E,P-12...................................................................................... 585 2) D65EX,PX-12.................................................................................... 587 H-10 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH....................................................... 589 H-11 DRAWBAR PULL IS WEEK,TRAVEL SPEED IS SLOW........................................................ 591 1) D65E,P-12...................................................................................... 591 2) D65EX,PX-12.................................................................................... 593 H-13 ABNORMAL NOISES IS GENERATED FROM AROUND HYDRAULIC PUMP OR HYDRAULIC,HSS PUMP.................... 594 H-14 SPEED OF ALL WORK EQUIPMENT IS SLOW (D65E,P-12).................................................. 595 H-15 NO WORK EQUIPMENT MOVES (D65E,P-12).............................................................. 597 H-16 ALL WORK EQUIPMENT LACKS POWER (D65E,P-12)....................................................... 597 H-17 TURNING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW (D65EX,PX-12).............................. 598 H-18 MACHINE CANNOT TURN AND NO WORK EQUIPMENT MOVES (D65EX,PX-12).................................... 600 H-19 TURNING AND ALL WORK EQUIPMENT LACKS POWER (D65EX,PX-12)......................................... 600 H-20 BLADE LIFTING SPEED IS SLOW OR LACKS POWER....................................................... 601 1) D65E,P-12...................................................................................... 601 2) D65EX,PX-12.................................................................................... 601 H-21 BLADE TILT SPEED IS SLOW OR LACKS POWER.......................................................... 602 1) D65E,P-12...................................................................................... 602 2) D65EX,PX-12.................................................................................... 602 H-22 HYDRAULIC DRIFT OF BLADE LIFY IS EXCESSIVE....................................................... 603 H-23 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE....................................................... 603 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................................. 604 TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)................................................. 605 E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO 0N................................ 606 E-2 LAMP DO NOT LIGHT UP.............................................................................. 612 a) FRONT LAMPS.................................................................................... 612 b) REAR LAMPS..................................................................................... 613 E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO ....................... 616 E-5 WIPER DOES NOT WORK............................................................................... 622 E-6 NO WASHER FLUID IS SPRAYED OUT.................................................................... 624 E-7 AIR CONDITION HAS NOT EFFECT...................................................................... 626 a) NO AIR COMES OUT............................................................................... 626 b) DOES NOT BECOME COOL .......................................................................... 630 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)........................................................ 634 TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)............................................ 635 M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON......................... 636 M-2 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT............. 636 M-3 PREHEATING DISPLAY IS ABNORMAL.................................................................... 637 a) PREHEATING MONITOR DOES NOT LIGHT UP........................................................... 637 b) PREHEATING MONITOR DOES NOT GO OUT............................................................. 637 M-4 CAUTION ITEMS LIGHT UP OR FLASH................................................................... 643 a) (CHARGE) LIGHTS UP OR FLASHES.................................................................. 643 b) WHEN STARTING SWITCH AT ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES.... 644 c) (COOLANT TEMPERATURE) FLASHES.................................................................. 645 d) (POWER TRAIN OIL TEMPERATURE) FLASHES.......................................................... 647 M-5 BUZZER IS ABNORMAL................................................................................ 649 a) CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND................................................ 649 b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS................................................... 649 M-6 WARNING LAMP IS ABNORMAL.......................................................................... 650 a) CAUTION ITEM FLASHING BUT LAMP DOES NOT FLASH.................................................. 650 b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES..................................................... 650 M-7 GAUGE IS ABNORMAL................................................................................. 651 a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE................................................ 651 b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE............................................... 652 c) ABNORMALITY IN FUEL LEVEL GAUGE................................................................ 653 M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED............................................... 657 M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)................................. 658 30 DISASSEMBLY AND ASSEMBLY....................................................................................... 660 METHOD OF USING MANUAL........................................................................................ 663 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................... 664 SPECIAL TOOL LIST............................................................................................. 666 SPECIAL TOOL SKETCH........................................................................................... 671 STARTING MOTOR................................................................................................ 672 REMOVAL................................................................................................... 672 INSTALLATION.............................................................................................. 672 ALTERNATOR ASSEMBLY........................................................................................... 673 REMOVAL................................................................................................... 673 INSTALLATION.............................................................................................. 673 ENGINE OIL COOLER CORE........................................................................................ 675 REMOVAL................................................................................................... 675 INSTALLATION.............................................................................................. 675 FUEL INJECTION PUMP ASSEMBLY.................................................................................. 676 REMOVAL................................................................................................... 676 INSTALLATION.............................................................................................. 677 WATER PUMP ASSEMBLY........................................................................................... 678 REMOVAL................................................................................................... 678 INSTALLATION.............................................................................................. 678 TURBOCHARGER ASSEMBLY......................................................................................... 680 REMOVAL................................................................................................... 680 INSTALLATION.............................................................................................. 680 NOZZLE HOLDER ASSEMBLY (D65P,EX,PX)........................................................................... 681 REMOVAL................................................................................................... 681 INSTALLATION.............................................................................................. 681 NOZZLE HOLDER ASSEMBLY (D65E)................................................................................. 682 REMOVAL................................................................................................... 682 INSTALLATION.............................................................................................. 682 THERMOSTAT ASSEMBLY........................................................................................... 683 REMOVAL................................................................................................... 683 INSTALLATION.............................................................................................. 683 CYLINDER HEAD ASSEMBLY (D65P,EX,PX)........................................................................... 685 REMOVAL................................................................................................... 685 INSTALLATION.............................................................................................. 689 CYLINDER HEAD ASSEMBLY (D65E)................................................................................. 697 REMOVAL................................................................................................... 697 INSTALLATION.............................................................................................. 700 ENGINE FRONT SEAL............................................................................................. 707 REMOVAL................................................................................................... 707 INSTALLATION.............................................................................................. 708 ENGINE REAR SEAL.............................................................................................. 709 REMOVAL................................................................................................... 709 INSTALLATION.............................................................................................. 710 AIR CONDITIONER COMPRESSOR ASSEMBLY........................................................................... 713 REMOVAL................................................................................................... 713 INSTALLATION.............................................................................................. 713 AIR CONDITIONER CONDENSER ASSEMBLY............................................................................ 714 REMOVAL................................................................................................... 714 INSTALLATION.............................................................................................. 714 FUEL TANK ASSEMBLY............................................................................................ 715 REMOVAL................................................................................................... 715 INSTALLATION.............................................................................................. 716 RADIATOR ASSEMBLY............................................................................................. 721 REMOVAL................................................................................................... 721 INSTALLATION.............................................................................................. 723 ENGINE ASSEMBLY (CAB SPECIFICATION)........................................................................... 724 REMOVAL................................................................................................... 724 INSTALLATION.............................................................................................. 727 ENGINE ASSEMBLY (CANOPY SPECIFICATION)........................................................................ 732 REMOVAL................................................................................................... 732 INSTALLATION.............................................................................................. 734 DAMPER ASSEMBLY............................................................................................... 738 REMOVAL................................................................................................... 738 INSTALLATION.............................................................................................. 740 POWER TRAIN UNIT ASSEMBLY (D65E,P)............................................................................ 742 REMOVAL................................................................................................... 742 INSTALLATION.............................................................................................. 747 POWER TRAIN UNIT ASSEMBLY (D65EX,PX).......................................................................... 748 REMOVAL................................................................................................... 748 INSTALLATION.............................................................................................. 753 POWER TRAIN UNIT (D65E,P)..................................................................................... 754 SEPARATION................................................................................................ 754 CONNECTION................................................................................................ 757 POWER TRAIN UNIT (D65EX,PX)................................................................................... 758 SEPARATION................................................................................................ 758 CONNECTION................................................................................................ 761 TORQUE CONVERTER ASSEMBLY..................................................................................... 762 DISASSEMBLY............................................................................................... 762 ASSEMBLY.................................................................................................. 764 PTO ASSEMBLY.................................................................................................. 767 DISASSEMBLY............................................................................................... 767 ASSEMBLY.................................................................................................. 770 TORQFLOW TRANSMISSION ASSEMBLY................................................................................ 774 DISASSEMBLY............................................................................................... 774 ASSEMBLY.................................................................................................. 793 STEERING CASE ASSEMBLY (D65E,P)............................................................................... 821 DISASSEMBLY............................................................................................... 821 ASSEMBLY.................................................................................................. 834 HSS ASSEMBLY (D65EX,PX)....................................................................................... 856 DISASSEMBLY............................................................................................... 856 ASSEMBLY.................................................................................................. 877 TORQUE CONVERTER VALVE ASSEMBLY............................................................................... 901 REMOVAL................................................................................................... 901 INSTALLATION.............................................................................................. 901 DISASSEMBLY............................................................................................... 902 ASSEMBLY.................................................................................................. 902 TRANSMISSION CONTROL VALVE ASSEMBLY........................................................................... 903 REMOVAL................................................................................................... 903 INSTALLATION.............................................................................................. 903 DISASSEMBLY............................................................................................... 905 ASSEMBLY.................................................................................................. 905 STEERING CONTROL VALVE ASSEMBLY (D65E,P)...................................................................... 909 REMOVAL................................................................................................... 909 INSTALLATION.............................................................................................. 909 DISASSEMBLY............................................................................................... 910 ASSEMBLY.................................................................................................. 912 BRAKE VALVE ASSEMBLY (D65EX,PX)............................................................................... 914 REMOVAL................................................................................................... 914 INSTALLATION.............................................................................................. 914 DISASSEMBLY............................................................................................... 915 ASSEMBLY.................................................................................................. 916 REDUCING VALVE ASSEMBLY (D65E,P).............................................................................. 917 REMOVAL................................................................................................... 917 INSTALLATION.............................................................................................. 917 DISASSEMBLY............................................................................................... 918 ASSEMBLY.................................................................................................. 918 HSS MOTOR ASSEMBLY (D65EX,PX)................................................................................. 919 REMOVAL................................................................................................... 919 INSTALLATION.............................................................................................. 919 DISASSEMBLY............................................................................................... 920 ASSEMBLY.................................................................................................. 924 SCAVENGING PUMP ASSEMBLY...................................................................................... 931 REMOVAL................................................................................................... 931 INSTALLATION.............................................................................................. 931 POWER TRAIN PUMP ASSEMBLY..................................................................................... 932 REMOVAL................................................................................................... 932 INSTALLATION.............................................................................................. 932 FINAL DRIVE ASSEMBLY.......................................................................................... 933 REMOVAL................................................................................................... 933 INSTALLATION.............................................................................................. 934 DISASSEMBLY............................................................................................... 935 ASSEMBLY.................................................................................................. 939 TRACK FRAME ASSEMBLY.......................................................................................... 944 REMOVAL................................................................................................... 944 INSTALLATION.............................................................................................. 945 RECOIL SPRING ASSENBLY........................................................................................ 946 REMOVAL................................................................................................... 946 INSTALLATION.............................................................................................. 946 DISASSEMBLY............................................................................................... 948 ASSEMBLY.................................................................................................. 950 IDLER ASSEMBLY................................................................................................ 954 REMOVAL................................................................................................... 954 INSTALLATION.............................................................................................. 954 DISASSEMBLY............................................................................................... 956 ASSEMBLY.................................................................................................. 957 TRACK ROLLER ASSEMBLY......................................................................................... 962 REMOVAL................................................................................................... 962 INSTALLATION.............................................................................................. 962 DISASSEMBLY............................................................................................... 963 ASSEMBLY.................................................................................................. 964 CARRIER ROLLER ASSEMBLY (D65P,PX)............................................................................. 966 REMOVAL................................................................................................... 966 INSTALLATION.............................................................................................. 966 CARRIER ROLLER ASSEMBLY (D65E,EX)............................................................................. 967 REMOVAL................................................................................................... 967 INSTALLATION.............................................................................................. 967 DISASSEMBLY (D65E,P,EX,PX)................................................................................ 968 ASSEMBLY (D65E,P,EX,PX)................................................................................... 969 TRACK SHOE.................................................................................................... 970 CHECKING BEFORE REMOVAL................................................................................... 970 REMOVAL (NORMAL).......................................................................................... 970 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME).................................................... 971 INSTALLATION.............................................................................................. 972 OVERALL DISASSEMBLY....................................................................................... 976 OVERALL ASSEMBLY.......................................................................................... 981 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.......................................................... 995 FIELD DISASSEMBLY OF ONE LINK............................................................................. 996 FIELD ASSEMBLY OF ONE LINK................................................................................ 997 PIVOT SHAFT ASSEMBLY..........................................................................................1003 REMOVAL...................................................................................................1003 INSTALLATION..............................................................................................1003 EQUALIZER BAR ASSEMBLY........................................................................................1004 REMOVAL...................................................................................................1004 INSTALLATION..............................................................................................1005 EQUALIZER SIDE BUSHING........................................................................................1006 REMOVAL...................................................................................................1006 INSTALLATION..............................................................................................1006 SEGMENT TEETH.................................................................................................1007 REMOVAL...................................................................................................1007 INSTALLATION..............................................................................................1007 WORK EQUIPMENT PUMP ASSEMBLY (D65E,P).........................................................................1008 REMOVAL...................................................................................................1008 INSTALLATION..............................................................................................1008 HSS, WORK EQUIPMENT PUMP ASSEMBLY (D65EX,PX)..................................................................1009 REMOVAL...................................................................................................1009 INSTALLATION..............................................................................................1009 DISASSEMBLY...............................................................................................1010 ASSEMBLY..................................................................................................1015 PPC PUMP ASSEMBLY.............................................................................................1024 REMOVAL...................................................................................................1024 INSTALLATION..............................................................................................1024 MAIN CONTROL VALVE ASSEMBLY...................................................................................1025 REMOVAL...................................................................................................1025 INSTALLATION..............................................................................................1025 DISASSEMBLY (3-SPOOL VALVE)...............................................................................1028 ASSEMBLY..................................................................................................1030 MAIN RELIEF VALVE.............................................................................................1036 REMOVAL...................................................................................................1036 INSTALLATION..............................................................................................1036 PPC VALVE ASSEMBLY............................................................................................1037 REMOVAL (FOR WORK EQUIPMENT)..............................................................................1037 INSTALLATION (FOR WORK EQUIPMENT).........................................................................1037 REMOVAL (D65EX,PX,FOR STEERING)...........................................................................1039 INSTALLATION (D65EX,PX,FOR STEERING)......................................................................1040 DISASSEMBLY (FOR WORK EQUIPMENT)..........................................................................1043 ASSEMBLY (FOR WORK EQUIPMENT).............................................................................1044 DISASSEMBLY (D65EX,PX,FOR STEERING) ......................................................................1045 ASSEMBLY (D65EX,PX,FOR STEERING)..........................................................................1046 PPC CHARGE RELIEF VALVE ASSEMBLY..............................................................................1047 REMOVAL...................................................................................................1047 INSTALLATION..............................................................................................1047 DISASSEMBLY...............................................................................................1048 ASSEMBLY..................................................................................................1048 SUCTION VALVE ASSEMBLY........................................................................................1049 REMOVAL...................................................................................................1049 INSTALLATION..............................................................................................1049 BLADE LIFT CYLINDER ASSEMBLY..................................................................................1050 REMOVAL...................................................................................................1050 INSTALLATION..............................................................................................1050 BLADE TILT CYLINDER ASSEMBLY..................................................................................1051 REMOVAL...................................................................................................1051 INSTALLATION..............................................................................................1051 HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER).................................................1052 DISASSEMBLY...............................................................................................1052 ASSEMBLY..................................................................................................1054 WORK EQUIPMENT ASSEMBLY.......................................................................................1057 REMOVAL...................................................................................................1057 INSTALLATION..............................................................................................1058 DISASSEMBLY...............................................................................................1059 ASSEMBLY..................................................................................................1061 RIPPER VALVE ASSEMBLY (OPT.)..................................................................................1063 DISASSEMBLY...............................................................................................1063 ASSEMBLY..................................................................................................1064 ROPS GUARD....................................................................................................1065 REMOVAL...................................................................................................1065 INSTALLATION..............................................................................................1065 OPERATOR'S CAB ASSEMBLY.......................................................................................1066 REMOVAL...................................................................................................1066 INSTALLATION..............................................................................................1067 CANOPY ASSEMBLY...............................................................................................1068 REMOVAL...................................................................................................1068 INSTALLATION..............................................................................................1068 DASHBOARD ASSEMBLY............................................................................................1069 REMOVAL...................................................................................................1069 INSTALLATION..............................................................................................1069 MONITOR ASSEMBLY..............................................................................................1070 REMOVAL...................................................................................................1070 INSTALLATION..............................................................................................1070 FLOOR FRAME ASSEMBLY (D65E,P).................................................................................1071 REMOVAL...................................................................................................1071 INSTALLATION..............................................................................................1074 FLOOR FRAME ASSEMBLY (D65EX,PX)...............................................................................1079 REMOVAL...................................................................................................1079 INSTALLATION..............................................................................................1082 40 MAINTENANCE STANDARD...........................................................................................1087 ENGINE MOUNT..................................................................................................1088 POWER TRAIN UNIT MOUNT........................................................................................1089 DAMPER, UNIVERSAL JOINT.......................................................................................1090 TORQUE CONVERTER, PTO.........................................................................................1091 TRANSMISSION..................................................................................................1093 TRANSMISSION CONTROL VALVE....................................................................................1097 MAIN RELIEF VALVE.............................................................................................1100 BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E,P-12).................................................1101 BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)......................................................1105 BEVEL GEAR SHAFT, HSS STEERING BRAKE (2/2) (D65EX,PX-12)......................................................1107 BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)......................................................1109 STEERING CONTROL VALVE (D65E,P-12)............................................................................1112 BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)...............................................................1113 POWER TRAIN, LUBRICATION PUMP.................................................................................1114 PPC PUMP......................................................................................................1115 PPC VALVE.....................................................................................................1117 FOR STEERING (D65EX,PX-12)................................................................................1117 FOR BLADE LIFT, BLADE TILT, RIPPER LIFT (D65E,P-12,D65EX,PX-12)...........................................1118 PPC CHARGE VALVE..............................................................................................1122 FINAL DRIVE...................................................................................................1123 HULL FRAME....................................................................................................1125 TRACK FRAME, RECOIL SPRING....................................................................................1126 IDLER.........................................................................................................1128 TRACK ROLLER..................................................................................................1131 CARRIER ROLLER................................................................................................1133 SPROCKET TOOTH PROFILE........................................................................................1134 TRACK SHOE (DRY TYPE).........................................................................................1135 TRACK SHOE (LUBRICATION TYPE).................................................................................1137 SUSPENSION....................................................................................................1139 HYDRAULIC PUMP (D65E,P-12)....................................................................................1143 HYDRAULIC, HSS PUMP (D65EX,PX-12).............................................................................1145 HSS MOTOR (D65EX,PX-12).......................................................................................1146 MAIN CONTROL VALVE............................................................................................1147 2+1-SPOOL VALVE (D65E,P-12)...............................................................................1147 3+1-SPOOL VALVE (D65EX,PX-12).............................................................................1157 WORK EQUIPMENT CYLINDER.......................................................................................1167 WORK EQUIPMENT................................................................................................1169 CUTTING EDGE, END BIT.........................................................................................1175 RIPPER........................................................................................................1176 90 OTHERS.........................................................................................................1177 SPECIFICATIONS................................................................................................1178 SPECIFICATION DRAWING.....................................................................................1178 SPECIFICATIONS............................................................................................1179 WEIGHT TABLE..............................................................................................1185 TABLE OF FUEL, COOLANT AND LUBRICANTS.....................................................................1188 STRUCTURE AND FUNCTION........................................................................................1189 REAR GUARD................................................................................................1189 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM...................................................................1190 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....................................................1191 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..................................................................1193 WORK EQUIPMENT CONTROL....................................................................................1194 MAIN CONTROL VALVE........................................................................................1195 TRIMMING DOZER............................................................................................1199 MAINTENANCE STANDARD..........................................................................................1200 MAIN CONTROL VALVE........................................................................................1200 WORK EQUIPMENT CYLINDER...................................................................................1209 TRIMMING DOZER............................................................................................1211 D65EX,PX-12 (FOR KA SPEC.)....................................................................................1212 STRUCTURE AND FUNCTION........................................................................................1213 ENGINE CONTROL............................................................................................1213 TRANSMISSION CONTROL......................................................................................1214 STEERING AND BRAKE CONTROL................................................................................1215 PPC CONTROL PIPING DIAGRAM................................................................................1216 TESTING AND ADJUSTING.........................................................................................1217 STANDARD VALUE TABLE FOR CHASSIS..........................................................................1217 ADJUSTING FUEL CONTROL LINKAGE............................................................................1219 ADJUSTING LINKAGE OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER, AND PARKING BRAKE LEVER.....................1221 TROUBLESHOOTING...............................................................................................1223 CONNECTOR TYPES AND MOUNTING LOCATIONS....................................................................1223 CONNECTOR POSITION DRAWING................................................................................1224 ELECTRIC CIRCUIT DIAGRAM......................................................................................1226 ELECTRIC CIRCUIT DIAGRAM FOR CAB..........................................................................1226 CAB SPECIFICATION.........................................................................................1227 CANOPY SPECIFICATION......................................................................................1228
DESCRIPTION:
KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001922 – PDF DOWNLOAD
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
S.S 22/12/24
