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KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001925 – PDF DOWNLOAD
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Description
KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001925 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001925 – PDF DOWNLOAD
Language : English
Pages : 1426
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001925 – PDF DOWNLOAD
COVER................................................................................................................ 1 CONTENTS............................................................................................................. 2 LIST OF REVISED PAGES................................................................................................ 3 SAFETY............................................................................................................... 9 SAFETY NOTICE.................................................................................................... 9 FOREWORD............................................................................................................. 11 GENERAL.......................................................................................................... 11 HOW TO READ THE SHOP MANUAL...................................................................................... 12 HOISTING INSTRUCTIONS............................................................................................ 13 METHOD OF DISASSEMBLING, CONNECTING PUSH-PULL TYPE COUPLER....................................................... 14 COATING MATERIALS................................................................................................ 16 STANDARD TIGHTENING TORQUE....................................................................................... 18 ELECTRIC WIRE CODE............................................................................................... 21 CONVERSION TABLE................................................................................................. 22 UNITS............................................................................................................ 28 01 GENERAL........................................................................................................... 29 GENERAL ASSEMBLY DRAWING......................................................................................... 30 SPECIFICATIONS................................................................................................... 34 WEIGHT TABLE..................................................................................................... 51 TABLE OF FUEL, COOLANT AND LUBRICANTS............................................................................ 57 10 STRUCTURE AND FUNCTION............................................................................................ 61 RADIATOR, OIL COOLER............................................................................................. 62 ENGINE CONTROL................................................................................................... 64 POWER TRAIN SYSTEM............................................................................................... 68 POWER TRAIN SKELETON............................................................................................. 69 POWER TRAIN UNIT................................................................................................. 74 POWER TRAIN HYDRAULIC PIPING DIAGRAM............................................................................. 76 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM............................................................................ 81 POWER TRAIN HYDRAULIC SYSTEM DIAGRAM............................................................................. 83 DAMPER, UNIVERSAL JOINT.......................................................................................... 91 TORQUE CONVERTER AND PTO......................................................................................... 94 TRANSMISSION CONTROL............................................................................................. 97 TRANSMISSION..................................................................................................... 102 TRANSMISSION CONTROL VALVE....................................................................................... 112 MAIN RELIEF VALVE................................................................................................ 121 LUBRICATION RELIEF VALVE......................................................................................... 123 STEERING, BRAKE CONTROL.......................................................................................... 124 BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E,P-12).................................................... 126 STEERING CONTROL VALVE (D65E,P-12)............................................................................... 142 STEERING BRAKE VALVE (D65E,P-12)................................................................................. 149 REDUCING VALVE................................................................................................... 153 STEERING AND BRAKE CONTROL (D65EX,PX-12)......................................................................... 155 BEVEL GEAR SHAFT, HSS STEERING AND BRAKE (D65EX,PX-12)........................................................... 158 BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12).................................................................. 181 SCAVENGING PUMP STRAINER......................................................................................... 185 POWER TRAIN OIL STRAINER......................................................................................... 186 POWER TRAIN OIL FILTER........................................................................................... 187 FINAL DRIVE...................................................................................................... 188 MAIN FRAME....................................................................................................... 195 TRACK FRAME...................................................................................................... 196 RECOIL SPRING.................................................................................................... 199 SUSPENSION....................................................................................................... 202 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM.......................................................................... 206 ANGLEDOZER................................................................................................... 206 STRAIGHT TILTDOZER........................................................................................... 208 POWER PITCH DOZER............................................................................................ 210 RIPPER....................................................................................................... 213 PPC CONTROL PIPING DIAGRAM....................................................................................... 214 WORK EQUIPMENT CONTROL........................................................................................... 220 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM......................................................................... 223 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.......................................................................... 225 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM............................................................ 239 STEERING AND WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM............................................................. 241 HYDRAULIC TANK AND FILTER........................................................................................ 255 HYDRAULIC, HSS PUMP (D65EX,PX-12)................................................................................ 260 PPC VALVE (for steering) (D65EX,PX-12)........................................................................... 276 PPC VALVE (for steering) (D65E,P-12)............................................................................. 283 PPC VALVE (for blade lift, tilt and ripper)...................................................................... 288 PPC CHARGE VALVE................................................................................................. 304 PPC LOCK VALVE................................................................................................... 306 MAIN CONTROL VALVE (2-SPOOL VALVE) (D65E,P-12)................................................................... 308 MAIN CONTROL VALVE (3-SPOOL VALVE) (D65EX,PX-12)................................................................. 352 POWER PITCH SELECTOR VALVE....................................................................................... 413 HSS MOTOR........................................................................................................ 416 OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT............................................................ 421 SUCTION VALVE.................................................................................................... 438 PISTON VALVE..................................................................................................... 443 WORK EQUIPMENT................................................................................................... 444 ELECTRICAL CIRCUIT DIAGRAM....................................................................................... 449 ENGINE CONTROL................................................................................................... 473 MACHINE MONITOR SYSTEM........................................................................................... 474 SENSORS.......................................................................................................... 478 20 TESTING AND ADJUSTING............................................................................................. 481 STANDARD VALUE TABLE FOR ENGINE.................................................................................. 482 STANDARD VALUE TABLE FOR CHASSIS................................................................................. 490 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM....................................................................... 520 TOOL LIST FOR TESTING AND ADJUSTING.............................................................................. 523 ADJUSTING VALVE CLEARANCE........................................................................................ 525 MEASURING COMPRESSION PRESSURE................................................................................... 526 MEASURING BLOWBY................................................................................................. 527 ADJUSTING FUEL INJECTION TIMING.................................................................................. 528 MEASURING EXHAUST COLOR.......................................................................................... 530 MEASURING BOOST PRESSURE......................................................................................... 531 MEASURING EXHAUST TEMPERATURE (D65P,EX,PX)....................................................................... 532 MEASURING ENGINE OIL PRESSURE.................................................................................... 533 MEASURING ENGINE SPEED........................................................................................... 533 TESTING FAN BELT TENSION......................................................................................... 534 MEASURING SPEED AT TORQUE CONVERTER STALL........................................................................ 535 ADJUSTING FUEL CONTROL LINKAGE................................................................................... 536 ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE (D65E,P)................. 542 ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE (D65EX,PX).................................. 550 ADJUSTING BRAKE PEDAL LINKAGE.................................................................................... 556 D65E,P....................................................................................................... 556 D65EX,PX..................................................................................................... 559 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE......................................................................... 560 ADJUSTING STRAIGHT TILTDOZER..................................................................................... 563 ADJUSTING PPC VALVE.............................................................................................. 565 MEASURING POWER TRAIN OIL PRESSURE............................................................................... 566 D65E,P....................................................................................................... 566 D65EX,PX..................................................................................................... 573 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE (D65E,P)................................................. 580 TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE (D65EX,PX)..................................... 581 TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE................................................................... 584 MEASURING OUTPUT PRESSURE OF PPC VALVE........................................................................... 586 MEASURING OIL LEAKAGE FROM HSS MOTOR (D65EX,PX).................................................................. 589 MEASURING LEAKAGE INSIDE CYLINDER................................................................................ 589 BLEEDING AIR FROM HYDRAULIC CYLINDER............................................................................. 590 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT.............................................................. 590 PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE.......................................................... 591 PROCEDURE FOR TESTING SENSORS.................................................................................... 592 TESTING AND ADJUSTING “OPEN” AND “CLOSE” LOCK AND STEADY REST OF OPERATOR’S CAB DOOR............................. 594 TROUBLESHOOTING.................................................................................................. 597 POINTS TO REMEMBER WHEN TROUBLESHOOTING...................................................................... 598 SEQUENCE OF EVENTS IN TROUBLESHOOTING........................................................................ 599 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE............................................................. 600 CHECKS BEFORE TROUBLESHOOTING................................................................................ 608 METHOD OF USING MATRIX TROUBLESHOOTING CHART................................................................. 610 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................... 614 TYPE OF CONNECTOR AND POSITION OF INSTALLATION............................................................... 616 CONNECTOR POSITION DRAWING................................................................................... 617 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................... 628 ELECTRICAL CIRCUIT DIAGRAMS FOR EACH SYSTEM.................................................................. 653 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................... 661 S-1 Starting performance is poor (Starting always takes time)............................................ 662 S-2 Engine does not start................................................................................ 663 ①Engine does not turn................................................................................ 663 ②Engine turns but no exhaust gas comes out (Fuel is not being injected).............................. 664 ③Exhaust gas comes out but engine does not start (Fuel is being injected)............................ 665 S-3 Engine does not pick up smoothly (Follow-up is poor)................................................. 666 S-4 Engine stops during operations....................................................................... 667 S-5 Engine does not rotate smoothly...................................................................... 668 S-6 Engine lacks output (no power)....................................................................... 669 S-7 Exhaust gas is black (incomplete combustion)......................................................... 670 S-8 Oil consumption is excessive (or exhaust gas is blue)................................................ 671 S-9 Oil becomes contaminated quickly..................................................................... 672 S-10 Fuel consumption is excessive....................................................................... 673 S-11 Oil is in cooling water, or water spurts back, or water level goes down............................. 674 S-12 Oil pressure lamp lights up (drop in oil pressure).................................................. 675 S-13 Oil level rises..................................................................................... 676 S-14 Water temperature becomes too high (overheating).................................................... 677 S-15 Abnormal noise is made.............................................................................. 678 S-16 Vibration is excessive.............................................................................. 679 TROUBLESHOOTING OF HYDRAULIC, MECHANICAL SYSTEMS (H MODE).................................................... 681 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEMS)........................................ 683 H-1 Brakes do not work................................................................................... 685 H-2 Machine does not turn (can travel in a straight line) (D65E,P-12).................................... 686 H-3 Turning speed is slow (cannot turn) or lacks power when turning (D65EX,PX-12)........................ 688 H-4 Overruns when turning (D65E,P-12).................................................................... 690 H-5 Can turn in only one direction (when steering and directional lever is operated) (D65E,P-12)......... 691 H-6 Excessive time lag................................................................................... 694 H-7 Machine can travel in only one direction (forward or reverse)........................................ 694 H-8 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd).................... 696 1) D65E,P-12......................................................................................... 696 2) D65EX,PX-12....................................................................................... 698 H-9 Machine does not move in any speed range............................................................. 700 1) D65E,P-12......................................................................................... 700 2) D65EX,PX-12....................................................................................... 702 H-10 Power train oil temperature rises too high.......................................................... 704 H-11 Lacks drawer pull, travel speed is slow............................................................. 706 1) D65E,P-12......................................................................................... 706 2) D65EX,PX-12....................................................................................... 708 H-13 Abnormal noise is generated from around hydraulic pump or hydraulic, HSS pump....................... 709 H-14 Speed of all work equipment is slow (D65E,P-12)..................................................... 710 H-15 No work equipment moves (D65E,P-12)................................................................. 713 H-16 All work equipment lacks power (D65E,P-12).......................................................... 713 H-17 Turning speed and speed of all work equipment is slow (D65EX,PX-12)................................. 714 H-18 Machine cannot turn and no work equipment moves (D65EX,PX-12)....................................... 717 H-19 Turning and all work equipment lacks power (D65EX,PX-12)............................................ 717 H-20 Blade lifting speed is slow or lacks power.......................................................... 718 1) D65E,P-12......................................................................................... 718 2) D65EX,PX-12....................................................................................... 718 H-21 Blade tilt speed is slow or lacks power............................................................. 719 1) D65E,P-12......................................................................................... 719 2) D65EX,PX-12....................................................................................... 719 H-22 Hydraulic drift or blade lift is excessive.......................................................... 720 H-23 Hydraulic drift or blade lift is excessive.......................................................... 720 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)................................................................ 721 TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM).................................................... 722 E-1 Starting motor is not cranked when starting switch is turned to ON................................... 724 E-2 Lamps do not light up................................................................................ 730 a) Front lamps....................................................................................... 730 b) Rear lamps........................................................................................ 731 E-4 Automatic preheating is not carried out when glow switch is turned to AUTO........................... 734 E-5 Wiper does not work.................................................................................. 740 E-6 No washer liquid is sprayed out...................................................................... 742 E-7 Air conditioner has no effect........................................................................ 744 a) No air comes out.................................................................................. 744 b) Does not become cool.............................................................................. 748 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)........................................................... 753 TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)............................................... 754 M-1 No display appears on the monitor panel when the starting switch is turned to ON..................... 755 M-2 When starting switch is turned ON, all monitor panel lamps light up and do not go out................ 755 M-3 Preheating display is abnormal....................................................................... 756 a) Preheating monitor does not light up.............................................................. 756 b) Preheating monitor does not go out................................................................ 756 M-4 Caution items light up or flash...................................................................... 762 a) (charge) lights up or flashes..................................................................... 762 b) When starting switch is at ON and engine is started (engine oil pressure) lights up or flashes.... 763 c) (coolant temperature) flashes..................................................................... 764 d) (power train oil temperature) flashes............................................................. 766 M-5 Buzzer is abnormal................................................................................... 768 a) Caution item flashes but buzzer does not sound.................................................... 768 b) Monitor display is normal, but buzzer sounds...................................................... 768 M-6 Warning lamp is abnormal............................................................................. 769 a) Caution item flashing but lamp does not flash..................................................... 769 b) Monitor display is normal but lamp flashes........................................................ 769 M-7 Gauge is abnormal.................................................................................... 770 a) Abnormality in engine coolant temperature gauge................................................... 770 b) Abnormality in power train oil temperature gauge.................................................. 771 c) Abnormality in fuel level gauge................................................................... 772 M-8 Service meter does not move after engine is started.................................................. 776 M-9 Monitor panel lighting does not light up (front lamps are normal).................................... 777 30 DISASSEMBLY AND ASSEMBLY.......................................................................................... 779 METHOD OF USING MANUAL........................................................................................... 783 PRECAUTIONS WHEN CARRYING OUT OPERATION.......................................................................... 784 SPECIAL TOOL LIST................................................................................................ 786 SKETCH OF SPECIAL TOOLS.......................................................................................... 793 STARTING MOTOR................................................................................................... 795 REMOVAL...................................................................................................... 795 INSTALLATION................................................................................................. 795 ALTERNATOR ASSEMBLY.............................................................................................. 796 REMOVAL...................................................................................................... 796 INSTALLATION................................................................................................. 796 ENGINE OIL COOLER CORE........................................................................................... 798 REMOVAL...................................................................................................... 798 INSTALLATION................................................................................................. 798 FUEL INJECTION PUMP ASSEMBLY..................................................................................... 799 REMOVAL...................................................................................................... 799 INSTALLATION................................................................................................. 800 WATER PUMP ASSEMBLY.............................................................................................. 801 REMOVAL...................................................................................................... 801 INSTALLATION................................................................................................. 801 TURBOCHARGER ASSEMBLY............................................................................................ 804 REMOVAL...................................................................................................... 804 INSTALLATION................................................................................................. 804 NOZZLE HOLDER ASSEMBLY (D65P,EX,PX).............................................................................. 805 REMOVAL...................................................................................................... 805 INSTALLATION................................................................................................. 805 NOZZLE HOLDER ASSEMBLY (D65E).................................................................................... 806 REMOVAL...................................................................................................... 806 INSTALLATION................................................................................................. 806 THERMOSTAT ASSEMBLY.............................................................................................. 807 REMOVAL...................................................................................................... 807 INSTALLATION................................................................................................. 807 CYLINDER HEAD ASSEMBLY (D65P,EX,PX).............................................................................. 810 REMOVAL...................................................................................................... 810 INSTALLATION................................................................................................. 814 CYLINDER HEAD ASSEMBLY (D65E).................................................................................... 822 REMOVAL...................................................................................................... 822 INSTALLATION................................................................................................. 825 ENGINE FRONT SEAL................................................................................................ 834 REMOVAL...................................................................................................... 834 INSTALLATION................................................................................................. 835 ENGINE REAR SEAL................................................................................................. 836 REMOVAL...................................................................................................... 836 INSTALLATION................................................................................................. 837 AIR CONDITIONER COMPRESSOR ASSEMBLY.............................................................................. 841 REMOVAL...................................................................................................... 841 INSTALLATION................................................................................................. 841 AIR CONDITIONER CONDENSER ASSEMBLY............................................................................... 842 REMOVAL...................................................................................................... 842 INSTALLATION................................................................................................. 842 FUEL TANK ASSEMBLY............................................................................................... 843 REMOVAL...................................................................................................... 843 INSTALLATION................................................................................................. 844 RADIATOR ASSEMBLY................................................................................................ 849 REMOVAL...................................................................................................... 849 INSTALLATION................................................................................................. 851 HYDRAULIC OIL COOLER ASSEMBLY.................................................................................... 851 REMOVAL...................................................................................................... 851 INSTALLATION................................................................................................. 851 ENGINE ASSEMBLY (Cab specification).............................................................................. 852 REMOVAL...................................................................................................... 852 INSTALLATION................................................................................................. 855 ENGINE ASSEMBLY (Canopy specification)........................................................................... 860 REMOVAL...................................................................................................... 860 INSTALLATION................................................................................................. 862 DAMPER ASSEMBLY.................................................................................................. 867 REMOVAL...................................................................................................... 867 INSTALLATION................................................................................................. 869 POWER TRAIN UNIT ASSEMBLY (D65E,P)............................................................................... 871 REMOVAL...................................................................................................... 871 INSTALLATION................................................................................................. 876 POWER TRAIN UNIT ASSEMBLY (D65EX,PX)............................................................................. 877 REMOVAL...................................................................................................... 877 INSTALLATION................................................................................................. 883 POWER TRAIN UNIT (D65E,P)........................................................................................ 884 SEPARATION................................................................................................... 884 CONNECTION................................................................................................... 887 POWER TRAIN UNIT (D65EX,PX)...................................................................................... 889 SEPARATION................................................................................................... 889 CONNECTION................................................................................................... 892 TORQUE CONVERTER ASSEMBLY........................................................................................ 893 DISASSEMBLY.................................................................................................. 893 ASSEMBLY..................................................................................................... 895 PTO ASSEMBLY..................................................................................................... 898 DISASSEMBLY.................................................................................................. 898 ASSEMBLY..................................................................................................... 901 TORQFLOW TRANSMISSION ASSEMBLY................................................................................... 905 DISASSEMBLY.................................................................................................. 905 ASSEMBLY..................................................................................................... 924 STEERING CASE ASSEMBLY (D65E,P).................................................................................. 952 DISASSEMBLY.................................................................................................. 952 ASSEMBLY..................................................................................................... 966 HSS ASSEMBLY (D65EX,PX).......................................................................................... 991 DISASSEMBLY.................................................................................................. 991 ASSEMBLY.....................................................................................................1012 TORQUE CONVERTER VALVE ASSEMBLY..................................................................................1037 REMOVAL......................................................................................................1037 INSTALLATION.................................................................................................1037 DISASSEMBLY..................................................................................................1038 ASSEMBLY.....................................................................................................1038 TRANSMISSION CONTROL VALVE ASSEMBLY..............................................................................1039 REMOVAL......................................................................................................1039 INSTALLATION.................................................................................................1039 DISASSEMBLY..................................................................................................1042 ASSEMBLY.....................................................................................................1042 STEERING CONTROL VALVE ASSEMBLY (D65E,P).........................................................................1047 REMOVAL......................................................................................................1047 INSTALLATION.................................................................................................1047 DISASSEMBLY..................................................................................................1048 ASSEMBLY.....................................................................................................1050 BRAKE VALVE ASSEMBLY (D65EX,PX)..................................................................................1052 REMOVAL......................................................................................................1052 INSTALLATION.................................................................................................1052 DISASSEMBLY..................................................................................................1053 ASSEMBLY.....................................................................................................1054 REDUCING VALVE ASSEMBLY (D65E,P).................................................................................1055 REMOVAL......................................................................................................1055 INSTALLATION.................................................................................................1055 DISASSEMBLY..................................................................................................1056 ASSEMBLY.....................................................................................................1056 HSS MOTOR ASSEMBLY (D65EX,PX)....................................................................................1057 REMOVAL......................................................................................................1057 INSTALLATION.................................................................................................1057 DISASSEMBLY..................................................................................................1058 ASSEMBLY.....................................................................................................1062 SCAVENGING PUMP ASSEMBLY.........................................................................................1069 REMOVAL......................................................................................................1069 INSTALLATION.................................................................................................1069 POWER TRAIN PUMP ASSEMBLY........................................................................................1070 REMOVAL......................................................................................................1070 INSTALLATION.................................................................................................1070 FUEL DRIVE ASSEMBLY..............................................................................................1071 REMOVAL......................................................................................................1071 INSTALLATION.................................................................................................1072 DISASSEMBLY..................................................................................................1075 ASSEMBLY.....................................................................................................1079 TRACK FRAME ASSEMBLY.............................................................................................1098 REMOVAL......................................................................................................1098 INSTALLATION.................................................................................................1099 RECOIL SPRING ASSEMBLY...........................................................................................1100 REMOVAL......................................................................................................1100 INSTALLATION.................................................................................................1100 DISASSEMBLY..................................................................................................1103 ASSEMBLY.....................................................................................................1105 IDLER ASSEMBLY...................................................................................................1109 REMOVAL......................................................................................................1109 INSTALLATION.................................................................................................1109 DISASSEMBLY..................................................................................................1112 ASSEMBLY.....................................................................................................1113 TRACK ROLLER ASSEMBLY............................................................................................1119 REMOVAL......................................................................................................1119 INSTALLATION.................................................................................................1119 DISASSEMBLY..................................................................................................1120 ASSEMBLY.....................................................................................................1121 CARRIER ROLLER ASSEMBLY (D65P,PX)................................................................................1123 REMOVAL......................................................................................................1123 INSTALLATION.................................................................................................1123 CARRIER ROLLER ASSEMBLY (D65E,EX)................................................................................1124 REMOVAL......................................................................................................1124 INSTALLATION.................................................................................................1124 DISASSEMBLY (D65E,P,EX,PX)...................................................................................1125 ASSEMBLY (D65E,P,EX,PX)......................................................................................1126 TRACK SHOE.......................................................................................................1127 CHECKING BEFORE REMOVAL......................................................................................1127 REMOVAL (NORMAL).............................................................................................1127 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME).......................................................1128 INSTALLATION.................................................................................................1129 OVERALL DISASSEMBLY..........................................................................................1134 OVERALL ASSEMBLY.............................................................................................1139 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.............................................................1153 FIELD DISASSEMBLY OF ONE LINK................................................................................1155 FIELD ASSEMBLY OF ONE LINK...................................................................................1156 PIVOT SHAFT ASSEMBLY.............................................................................................1162 REMOVAL......................................................................................................1162 名称未設定........................................................................................................1162 EQUALIZER BAR ASSEMBLY...........................................................................................1163 REMOVAL......................................................................................................1163 INSTALLATION.................................................................................................1164 EQUALIZER BAR SIDE BUSHING.......................................................................................1165 REMOVAL......................................................................................................1165 INSTALLATION.................................................................................................1165 SEGMENT TEETH....................................................................................................1166 REMOVAL......................................................................................................1166 INSTALLATION.................................................................................................1166 WORK EQUIPMENT PUMP ASSEMBLY (D65E,P)............................................................................1167 REMOVAL......................................................................................................1167 INSTALLATION.................................................................................................1167 HSS, WORK EQUIPMENT PUMP ASSEMBLY (D65EX,PX).....................................................................1168 REMOVAL......................................................................................................1168 INSTALLATION.................................................................................................1168 DISASSEMBLY..................................................................................................1169 ASSEMBLY.....................................................................................................1174 PPC PUMP ASSEMBLY................................................................................................1183 REMOVAL......................................................................................................1183 INSTALLATION.................................................................................................1183 MAIN CONTROL VALVE ASSEMBLY......................................................................................1184 REMOVAL......................................................................................................1184 INSTALLATION.................................................................................................1184 DISASSEMBLY (3-SPOOL VALVE)..................................................................................1188 ASSEMBLY.....................................................................................................1190 MAIN RELIEF VALVE................................................................................................1196 REMOVAL......................................................................................................1196 INSTALLATION.................................................................................................1196 PPC VALVE ASSEMBLY...............................................................................................1197 REMOVAL (FOR WORK EQUIPMENT).................................................................................1197 INSTALLATION (FOR WORK EQUIPMENT)............................................................................1197 REMOVAL (D65EX,PX, FOR STEERING).............................................................................1200 INSTALLATION (D65EX,PX, FOR STEERING)........................................................................1201 DISASSEMBLY (FOR WORK EQUIPMENT).............................................................................1204 ASSEMBLY (FOR WORK EQUIPMENT)................................................................................1205 DISASSEMBLY (D65EX,PX, FOR STEERING).........................................................................1206 ASSEMBLY (D65EX,PX, FOR STEERING)............................................................................1207 PPC CHARGE RELIEF VALVE ASSEMBLY.................................................................................1208 REMOVAL......................................................................................................1208 INSTALLATION.................................................................................................1208 DISASSEMBLY..................................................................................................1209 ASSEMBLY.....................................................................................................1209 SUCTION VALVE....................................................................................................1210 REMOVAL......................................................................................................1210 INSTALLATION.................................................................................................1210 BLADE LIFT CYLINDER ASSEMBLY.....................................................................................1212 REMOVAL......................................................................................................1212 INSTALLATION.................................................................................................1212 BLADE TILT CYLINDER ASSEMBLY.....................................................................................1213 REMOVAL......................................................................................................1213 INSTALLATION.................................................................................................1213 HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER)....................................................1214 DISASSEMBLY..................................................................................................1214 ASSEMBLY.....................................................................................................1216 WORK EQUIPMENT ASSEMBLY..........................................................................................1219 REMOVAL......................................................................................................1219 INSTALLATION.................................................................................................1220 DISASSEMBLY..................................................................................................1221 ASSEMBLY.....................................................................................................1223 RIPPER VALVE ASSEMBLY (OPT.).....................................................................................1225 DISASSEMBLY..................................................................................................1225 ASSEMBLY.....................................................................................................1226 ROPS GUARD.......................................................................................................1227 REMOVAL......................................................................................................1227 INSTALLATION.................................................................................................1227 OERATOR’S CAB ASSEMBLY...........................................................................................1228 REMOVAL......................................................................................................1228 INSTALLATION.................................................................................................1229 CANOPY ASSEMBLY..................................................................................................1230 REMOVAL......................................................................................................1230 INSTALLATION.................................................................................................1230 DASHBOARD ASSEMBLY...............................................................................................1232 REMOVAL......................................................................................................1232 INSTALLATION.................................................................................................1232 MONITOR ASSEMBLY.................................................................................................1233 REMOVAL......................................................................................................1233 INSTALLATION.................................................................................................1233 FLOOR FRAME ASSEMBLY (D65E,P)....................................................................................1234 REMOVAL......................................................................................................1234 INSTALLATION.................................................................................................1237 FLOOR FRAME ASSEMBLY (D65EX,PX)..................................................................................1242 REMOVAL......................................................................................................1242 INSTALLATION.................................................................................................1245 40 MAINTENACE STANDARD...............................................................................................1251 ENGINE MOUNT.....................................................................................................1252 POWER TRAIN UNIT MOUNT...........................................................................................1253 DAMPER, UNIVERSAL JOINT..........................................................................................1254 TORQUE CONVERTER, PTO............................................................................................1256 TRANSMISSION.....................................................................................................1258 TRANSMISSION CONTROL VALVE.......................................................................................1262 MAIN RELIEF VALVE................................................................................................1265 BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E,P-12)....................................................1267 BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65E,P-12)...........................................................1273 BEVEL GEAR SHAFT, HSS STEERING BRAKE (2/2) (D65EX,PX-12).........................................................1276 BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12).........................................................1278 STEERING CONTROL VALVE (D65E,P-12)...............................................................................1282 BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)..................................................................1283 POWER TRAIN, LUBRICATION PUMP....................................................................................1284 PPC PUMP.........................................................................................................1285 PPC VALVE........................................................................................................1288 FOR STEERING (D65EX,PX-12)...................................................................................1288 FOR BLADE LIFT, BLADE TILT, RIPPER LIFT (D65E,P-12・D65EX,PX-12)..............................................1289 PPC CHARGE VALVE.................................................................................................1294 FINAL DRIVE......................................................................................................1296 FULL-SCALE DRAWING OF SPROCKET TOOTH SHAPE.......................................................................1302 HULL FRAME.......................................................................................................1304 TRACK FRAME, RECOIL SPRING.......................................................................................1305 IDLER............................................................................................................1308 TRACK ROLLER.....................................................................................................1312 CARRIER ROLLER...................................................................................................1314 TRACK SHOE (DRY TYPE)............................................................................................1316 TRACK SHOE (LUBRICATED TYPE).....................................................................................1318 SUSPENSION.......................................................................................................1320 HYDRAULIC PUMP (D65E,P-12).......................................................................................1324 HYDRAULIC, HSS PUMP (D65EX,PX-12)................................................................................1327 HSS MOTOR (D65EX,PX-12)..........................................................................................1328 MAIN CONTROL VALVE...............................................................................................1329 2+1-SPOOL VALVE (D65E,P-12)..................................................................................1329 3+1-SPOOL VALVE (D65EX,PX-12)................................................................................1341 WORK EQUIPMENT CYLINDER..........................................................................................1352 WORK EQUIPMENT...................................................................................................1354 CUTTING EDGE, END BIT ..........................................................................................1360 RIPPER...........................................................................................................1361 90 OTHERS............................................................................................................1363 TRIMMING DOZER DDM060-4A.........................................................................................1364 SPECIFICATINS................................................................................................1364 SPECIFICATION DRAWING....................................................................................1364 SPECIFICATIONS...........................................................................................1365 WEIGHT TABLE.............................................................................................1371 TABLE OF FUEL, COOLANT AND LUBRICANTS....................................................................1375 STRUCTURE AND FUNCTION.......................................................................................1376 REAR GUARD...............................................................................................1376 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM..................................................................1377 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM....................................................1379 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.................................................................1383 WORK EQUIPMENT CONTROL...................................................................................1385 MAIN CONTROL VALVE.......................................................................................1386 TRIMMING DOZER...........................................................................................1393 MAINTENANCE STANDARD.........................................................................................1395 MAIN CONTROL VALVE.......................................................................................1395 WORK EQUIPMENT CYLINDER..................................................................................1404 TRIMMING DOZER...........................................................................................1406 D65EX,PX-12 FOR KA SPEC..........................................................................................1407 STRUCTURE AND FUNCTION.......................................................................................1408 ENGINE CONTROL...........................................................................................1408 TRANSMISSION CONTROL.....................................................................................1409 STEERING AND BRAKE CONTROL...............................................................................1410 PPC CONTROL PIPING DIAGRAM...............................................................................1411 TESTING AND ADJUSTING........................................................................................1412 STANDARD VALUE TABLE FOR CHASSIS.........................................................................1412 ADJUSTING FUEL CONTROL LINKAGE...........................................................................1414 ADJUSTING LINKAGES OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER AND PARKING BRAKE LEVER....................1416 TROUBLESHOOTING..............................................................................................1418 CONNECTOR TYPES AND MOUNTING LOCATIONS...................................................................1418 CONNECTOR POSITION DRAWING...............................................................................1420 ELECTRIC CIRCUIT DIAGRAM.....................................................................................1422 ELECTRIC CIRCUIT DIAGRAM FOR CAB.........................................................................1422 CAB SPECIFICATION........................................................................................1423 CANOPY SPECIFICATION.....................................................................................1425
DESCRIPTION:
KOMATSU D65E,P-12 D65EX,PX-12 SHOP MANUAL SEBM001925 – 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 26/12/24
