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KOMATSU D65EX-12 D65PX-12 SHOP MANUAL SEBM027202 – PDF DOWNLOAD
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Description
KOMATSU D65EX-12 D65PX-12 SHOP MANUAL SEBM027202 – PDF DOWNLOAD
FILE DETAILS:
KOMATSU D65EX-12 D65PX-12 SHOP MANUAL SEBM027202 – PDF DOWNLOAD
Language : English
Pages : 784
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
KOMATSU D65EX-12 D65PX-12 SHOP MANUAL SEBM027202 – PDF DOWNLOAD
COVER................................................................................................................................. 1 CONTENTS.............................................................................................................................. 2 01 GENERAL............................................................................................................................ 26 GENERAL ASSEMBLY DRAWING.......................................................................................................... 27 SPECIFICATIONS.................................................................................................................... 31 WEIGHT TABLE...................................................................................................................... 36 TABLE OF FUEL, COOLANT AND LUBRICANTS............................................................................................. 38 10 STRUCTURE AND FUNCTION............................................................................................................. 39 RADIATOR, OIL COOLER.............................................................................................................. 40 ENGINE CONTROL.................................................................................................................... 42 POWER TRAIN SYSTEM................................................................................................................ 43 POWER TRAIN SKELETON.............................................................................................................. 44 POWER TRAIN UNIT.................................................................................................................. 45 POWER TRAIN HYDRAULIC PIPING DIAGRAM.............................................................................................. 46 DAMPER, UNIVERSAL JOINT........................................................................................................... 47 TORQUE CONVERTER AND PTO.......................................................................................................... 49 TRANSMISSION CONTROL.............................................................................................................. 51 TRANSMISSION...................................................................................................................... 52 TRANSMISSION CONTROL VALVE........................................................................................................ 59 MAIN RELIEF VALVE................................................................................................................. 64 LUBRICATION RELIEF VALVE.......................................................................................................... 66 STEERING AND BRAKE CONTROL........................................................................................................ 67 BEVEL GEAR SHAFT, HSS STEERING AND BRAKE.......................................................................................... 68 BEVEL GEAR SHIFT, HSS BRAKE VALVE................................................................................................. 79 FINAL DRIVE....................................................................................................................... 83 MAIN FRAME........................................................................................................................ 86 TRACK FRAME....................................................................................................................... 87 RECOIL SPRING..................................................................................................................... 88 SUSPENSION........................................................................................................................ 89 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM........................................................................................... 91 PPC CONTROL PIPING DIAGRAM........................................................................................................ 95 WORK EQUIPMENT CONTROL............................................................................................................ 96 HYDRAULIC TANK AND FILTER......................................................................................................... 97 HYDRAULIC, HSS PUMP............................................................................................................... 99 PPC VALVE.........................................................................................................................114 PPC VALVE.........................................................................................................................121 PPC CHARGE VALVE..................................................................................................................129 MAIN CONTROL VALVE................................................................................................................131 POWER PITCH SELECTOR VALVE........................................................................................................157 HSS MOTOR.........................................................................................................................160 OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT.............................................................................165 SUCTION VALVE.....................................................................................................................173 PISTON VALVE......................................................................................................................175 ENGINE CONTROL....................................................................................................................176 ENGINE CONTROLLER.................................................................................................................180 VEHICLE CONTROLLER................................................................................................................182 MONITOR SYSTEM....................................................................................................................184 20 TESTING AND ADJUSTING..............................................................................................................192 STANDARD VALUE TABLE FOR ENGINE RELATED PARTS.....................................................................................193 STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS....................................................................................194 STANDARD VALUE TABLE FOR ELECTRICAL PARTS.........................................................................................204 TESTING AND ADJUSTING.............................................................................................................209 TOOL LIST FOR TESTING AND ADJUSTING...........................................................................................210 MEASURING ENGINE SPEED........................................................................................................212 MEASURING TORQUE CONVERTER STALL SPEED........................................................................................213 MEASURING AIR SUPPLY PRESSURE (BOOST PRESSURE)................................................................................214 MEASURING EXHAUST TEMPERATURE.................................................................................................215 MEASURING EXHAUST COLOR.......................................................................................................216 ADJUSTING VALVE CLEARANCE.....................................................................................................217 MEASURING COMPRESSION PRESSURE................................................................................................218 MEASURING BLOW-BY PRESSURE....................................................................................................220 MEASURING ENGINE OIL PRESSURE.................................................................................................221 MEASURING FUEL PRESSURE.......................................................................................................222 HANDLING EQUIPMENT IN FUEL SYSTEM.............................................................................................223 RELEASING REMAINING PRESSURE IN FUEL SYSTEM...................................................................................223 BLEEDING AIR FROM FUEL CIRCUIT................................................................................................224 REDUCED CYLINDER MODE OPERATION FOR ENGINE....................................................................................225 CHECKING FOR LEAKAGE IN FUEL SYSTEM...........................................................................................226 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL.............................................................................227 ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE..........................................................228 ADJUSTING BRAKE PEDAL LINKAGE.................................................................................................230 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE......................................................................................231 ADJUSTING STRAIGHT TILTDOZER..................................................................................................232 ADJUSTING PPC VALVE...........................................................................................................234 MEASURING POWER TRAIN OIL PRESSURE............................................................................................235 MEASURING POWER TRAIN OIL PRESSURE............................................................................................237 TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE.............................................................240 TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE................................................................................242 MEASURING OUTPUT PRESSURE OF PPC VALVE........................................................................................243 MEASURING OIL LEAKAGE FROM HSS MOTOR..........................................................................................244 MEASURING LEAKAGE INSIDE CYLINDER.............................................................................................244 BLEEDING AIR FROM HYDRAULIC CYLINDER..........................................................................................244 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT...........................................................................245 PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE.......................................................................245 PROCEDURE FOR TESTING SENSORS.................................................................................................246 TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATOR'S CAB DOOR..........................................248 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS).....................................................................................251 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER.........................................................................283 ADJUSTMENT METHOD OF REPLACED CONTROLLER......................................................................................283 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM......................................................................284 TROUBLESHOOTING...................................................................................................................286 POINTS TO REMEMBER WHEN TROUBLESHOOTING.......................................................................................287 SEQUENCE OF EVENTS IN TROUBLESHOOTING.........................................................................................288 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE..............................................................................289 CHECKS BEFORE TROUBLESHOOTING.................................................................................................297 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING..............................................................................298 CONNECTOR ALLOCATION DRAWING AND ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM...................................................301 CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM..................................................................................307 CIRCUIT DRAWING FOR MACHINE CONTROLLER SYSTEM.................................................................................309 CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM......................................................................................311 CIRCUIT DRAWING FOR OTHERS SYSTEM.............................................................................................313 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS....................................................................................315 TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE).....................................................................338 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST.............................................................................340 TROUBLE CODE TABLE........................................................................................................341 ERROR CODE [A000N1] (ENGINE: OVERRUN (N1))................................................................................342 ERROR CODE [AB00MA] (ALTERNATOR: MAIFUNCTION (MA))........................................................................343 ERROR CODE [AD00L2] (COMMON RAIL: SEE THE LIST. (L2)).....................................................................344 ERROR CODE [AD00MA] (COMMON RAIL: DEFECTIVE FUNCTION (MA))................................................................345 ERROR CODE [AD10L3] (FUEL SUPPLY PUMP: SEE THE LIST. (L3))................................................................345 ERROR CODE [AD10MA] (FUEL SUPPLY PUMP: DEFECTIVE FUNCTION (MA))...........................................................348 ERROR CODE [AD10MB] (FUEL SUPPLY PUMP: FUNCTION REDUCTION (MB))...........................................................348 ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1: DISCONNECTION IN WIRING (KA))...........................................349 ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1: SHORT CIRCUIT (KB)).....................................................350 ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN WIRING (KA))...........................................351 ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2: DISCONNECTION IN SHORT (KB))............................................352 ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))................................................353 ERROR CODE [ADAZKB] (NO.1, 2, AND 3 INJECTOR SOLENOIDS: SHORT (KB)).......................................................354 ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))................................................356 ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))................................................357 ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID: DISCONNECTION IN WIRING (KA))................................................358 ERROR CODE [ADDZKB] (NO.4, 5, AND 6 INJECTOR SOLENOIDS: SHORT (KB)).......................................................359 ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID: DISCONNECTION (KA)).....................................................361 ERROR CODE [ADF1KA] (NO.6 FUEL INJECTOR SOLENOID: DISCONNECTION (KA)).....................................................362 ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG)).............................................................363 ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS)).....................................................................364 ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS)).......................................................................365 ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS))........................................................................366 ERROR CODE [D110KA] (BATTERY RELAY: SHORT CIRCUIT (KA))...................................................................367 ERROR CODE [D110KB] (BATTERY RELAY: DISCONNECTION (KB))...................................................................368 ERROR CODE [D182KZ] (INTAKE AIR HEATER RELAY CIRCUIT: DISCONNECTION OR SHORT CIRCUIT (KZ))................................369 ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY: SHORT CIRCUIT (KB)).............................................371 ERROR CODE [D5ZFKA] (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION (KA)).....................................................372 ERROR CODE [D5ZFKB] (TRANSMISSION NEUTRAL SIGNAL: SHORT CIRCUIT (KB)).....................................................373 ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR)).......................................374 ERROR CODE [DAQ0KK] (TRANSMISSION CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK))........................................376 ERROR CODE [DAQ0KT] (TRANSMISSION CONTROLLER: ABNORMALITY IN CONTROLLER (KT)).............................................376 ERROR CODE [DAQ5KK] (TRANSMISSION CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK)).............377 ERROR CODE [DAQ6KK] (TRANSMISSION CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))....................377 ERROR CODE [DAQ9KQ] (TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)).......................377 ERROR CODE [DB20KT] (ENGINE CONTROLLER POWER SUPPLY: ABNORMALITY IN CONTROLLER (KT))......................................378 ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))............................379 ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT: TYPE SELECT SIGNAL INCONSISTENCY (KQ))................................381 ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL: MALFUNCTION (MA))....................................382 ERROR CODE [DB2RKR] (ENGINE CONTROLLER CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR))...................................383 ERROR CODE [DB2RMC] (ENGINE CONTROLLER DETECTION: DEFECTIVE CAN COMMUNICATION (MC)).......................................385 ERROR CODE [DB30KK] (MACHINE CONTROLLER: SOURCE VOLTAGE REDUCTION/INPUT (KK)).............................................386 ERROR CODE [DB30KT] (MACHINE CONTROLLER: ABNORMALITY IN CONTROLLER (KT))..................................................387 ERROR CODE [DB35KK] (MACHINE CONTROLLER POTENTIOMETER POWER SUPPLY: SOURCE VOLTAGE REDUCTION/INPUT (KK))..................388 ERROR CODE [DB36KK] (MACHINE CONTROLLER SENSOR POWER SUPPLY: SOURCE VOLTAGE REDUCTION INPUT (KK)).........................389 ERROR CODE [DB39KQ] (MACHINE CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ))............................390 ERROR CODE [DD11KB] (STARTING SWITCH: SHORT CIRCUIT (KB)).................................................................391 ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH: INCONSISTENT WITH MACHINE STATE (L6))....................................392 ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))....394 ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE): INCONSISTENT WITH MACHINE STATE (L6)).........395 ERROR CODE [DGE4KX] (FUEL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))...................................396 ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))..........................397 ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))............................................398 ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR: INPUT IS OUT OF NORMAL RANGE (KX))......................................400 ERROR CODE [DK10KX] (FUEL CONTROL DIAL: INPUT IS OUT OF NORMAL RANGE (KX))................................................402 ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER: INPUT IS OUT OF NORMAL RANGE (KX)).......................................404 ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR: INPUT SIGNAL OF TWO SYSTEMS INCONSISTENCY (LC))..............................406 ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR: INPUT SIGNAL OF TWO SYSTEMS INCONSISTENCY (LC))...............................408 ERROR CODE [DNCAKA] (TRANSMISSION FNR DETECTION LIMIT SWITCH: DISCONNECTION (KA)).........................................409 ERROR CODE [DNCAKB] (TRANSMISSION FNR DETECTION LIMIT SWITCH: SHORT CIRCUIT (KB)).........................................411 ERROR CODE [DNCBKA] (TRANSMISSION GEAR SHIFT DETECTION LIMIT SWITCH: DISCONNECTION (KA))..................................413 ERROR CODE [DNCBKB] (TRANSMISSION GEAR SHIFT DETECTION LIMIT SWITCH: SHORT CIRCUIT (KB))..................................414 ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))..................................................................415 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE).................................................................................416 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST.............................................................................417 E-1 THE STARTING MOTOR DOES NOT ROTATE....................................................................................418 E-2 THE INTAKE AIR HEATER DOES NOT OPERATE................................................................................420 E-3 THE HEADLAMP DOES NOT COME ON.........................................................................................423 E-4 THE REAR LAMP DOES NOT COME ON........................................................................................425 E-5 THE AIR CONDITIONER DOES NOT OPERATE..................................................................................426 E-6 THE WIPER DOES NOT OPERATE............................................................................................432 E-7 NO FLUID COMES OUT FROM WINDOW WASHER.................................................................................434 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)...................................................................436 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................437 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC, MECHANICAL SYSTEMS).........................................................438 H-1 BRAKE DOES NOT WORK...................................................................................................440 H-2 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING.......................................................441 H-3 EXCESSIVE TIME LAG....................................................................................................442 H-4 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE).........................................................442 H-5 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD).....................................443 M-6 MACHINE DOES NOT MOVE IN ANY SPEED RANGE..............................................................................444 H-7 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH............................................................................445 H-8 DRAWBAR PULL IS WEAK, TRAVEL SPEED IS SLOW............................................................................446 H-9 ABNORMAL NOISE IS GENERATED FROM AROUND HYDRAULIC AND HSS PUMP........................................................447 H-10 TURING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW.................................................................448 H-11 MACHINE CANNOT TURN AND NO WORK EQUIPMENT MOVES......................................................................449 H-12 TURNING AND ALL WORK EQUIPMENT LACKS POWER...........................................................................450 H-13 BLADE LIFTING SPEED IS SLOW OR LACKS POWER...........................................................................451 H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER..............................................................................452 H-15 HYDRAULIC DRIFT OF BLADE LIFT IS EXCESSIVE...........................................................................453 H-16 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE...........................................................................453 TROUBLESHOOTING OF MONITOR SYSTEM (M-MODE)....................................................................................454 METHOD OF USING TROUBLESHOOTING CHARTS....................................................................................455 TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)................................................................456 M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON ............................................457 M-2 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT.................................457 M-3 PREHEATING DISPLAY IS ABNORMAL........................................................................................458 M-4 CAUTION ITEMS FLASH...................................................................................................459 M-5 BUZZER IS ABNORMAL....................................................................................................460 M-6 WARNING LAMP IS ABNORMAL..............................................................................................461 M-7 GAUGE IS ABNORMAL.....................................................................................................462 M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED...................................................................466 M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMP ARE NORMAL)......................................................467 30 DISASSEMBLY AND ASSEMBLY...........................................................................................................468 METHOD OF USING MANUAL............................................................................................................470 PRECAUTIONS WHEN CARRYING OUT OPERATION...........................................................................................471 SPECIAL TOOL LIST.................................................................................................................473 SPECIAL TOOL SKETCH...............................................................................................................478 FUEL SUPPLY PUMP ASSEMBLY.........................................................................................................480 REMOVAL.......................................................................................................................480 INSTALLATION..................................................................................................................481 NOZZLE HOLDER ASSEMBLY............................................................................................................483 REMOVAL.......................................................................................................................483 INSTALLATION..................................................................................................................484 NOZZLE TIP........................................................................................................................486 REMOVAL.......................................................................................................................486 INSTALLATION..................................................................................................................488 CYLINDER HEAD ASSEMBLY............................................................................................................490 REMOVAL.......................................................................................................................490 INSTALLATION..................................................................................................................495 FUEL TANK ASSEMBLY................................................................................................................498 REMOVAL.......................................................................................................................498 INSTALLATION..................................................................................................................499 RADIATOR ASSEMBLY.................................................................................................................500 REMOVAL.......................................................................................................................500 INSTALLATION..................................................................................................................502 HYDRAULIC OIL COOLER ASSEMBLY.....................................................................................................502 REMOVAL.......................................................................................................................502 INSTALLATION..................................................................................................................502 ENGINE ASSEMBLY (CAB SPECIFICATION)...............................................................................................503 REMOVAL.......................................................................................................................503 INSTALLATION..................................................................................................................506 POWER TRAIN UNIT ASSEMBLY.........................................................................................................507 REMOVAL.......................................................................................................................507 INSTALLATION..................................................................................................................512 POWER TRAIN UNIT..................................................................................................................513 SEPARATION....................................................................................................................513 CONNECTION....................................................................................................................515 TORQUE CONVERTER ASSEMBLY.........................................................................................................516 DISASSEMBLY...................................................................................................................516 ASSEMBLY......................................................................................................................518 PTO ASSEMBLY......................................................................................................................521 DISASSEMBLY...................................................................................................................521 ASSEMBLY......................................................................................................................524 TORQFLOW TRANSMISSION ASSEMBLY....................................................................................................528 DISASSEMBLY...................................................................................................................528 TORQUE TRANSMISSION ASSEMBLY......................................................................................................538 ASSEMBLY......................................................................................................................538 HSS ASSEMBLY......................................................................................................................552 DISASSEMBLY...................................................................................................................552 ASSEMBLY......................................................................................................................563 TORQUE CONVERTER VALVE ASSEMBLY...................................................................................................577 REMOVAL.......................................................................................................................577 INSTALLATION..................................................................................................................577 DISASSEMBLY...................................................................................................................578 ASSEMBLY......................................................................................................................578 TRANSMISSION CONTROL VALVE ASSEMBLY...............................................................................................579 REMOVAL.......................................................................................................................579 TRANSMISSION CONTROL VALVE........................................................................................................579 INSTALLATION .................................................................................................................579 TRANSMISSION CONTROL VALVE ASSEMBLY...............................................................................................581 DISASSEMBLY...................................................................................................................581 ASSEMBLY......................................................................................................................581 BRAKE VALVE ASSEMBLY..............................................................................................................583 REMOVAL.......................................................................................................................583 INSTALLATION..................................................................................................................583 DISASSEMBLY...................................................................................................................584 ASSEMBLY......................................................................................................................585 HSS MOTOR ASSEMBLY................................................................................................................586 REMOVAL.......................................................................................................................586 INSTALLATION..................................................................................................................586 DISASSEMBLY...................................................................................................................587 ASSEMBLY......................................................................................................................591 SCAVENGING PUMP ASSEMBLY..........................................................................................................598 REMOVAL.......................................................................................................................598 INSTALLATION..................................................................................................................598 POWER TRAIN PUMP ASSEMBLY.........................................................................................................599 REMOVAL.......................................................................................................................599 INSTALLATION..................................................................................................................599 FINAL DRIVE ASSEMBLY..............................................................................................................600 REMOVAL.......................................................................................................................600 INSTALLATION..................................................................................................................601 DISASSEMBLY...................................................................................................................602 ASSEMBLY......................................................................................................................606 TRACK FRAME ASSEMBLY..............................................................................................................611 REMOVAL.......................................................................................................................611 INSTALLATION..................................................................................................................612 RECOIL SPRING ASSEMBLY............................................................................................................613 REMOVAL.......................................................................................................................613 INSTALLATION..................................................................................................................613 DISASSEMBLY...................................................................................................................614 ASSEMBLY......................................................................................................................616 IDLER ASSEMBLY....................................................................................................................617 REMOVAL.......................................................................................................................617 INSTALLATION..................................................................................................................617 DISASSEMBLY...................................................................................................................618 ASSEMBLY......................................................................................................................619 TRACK ROLLER ASSEMBLY.............................................................................................................624 REMOVAL.......................................................................................................................624 INSTALLATION..................................................................................................................624 DISASSEMBLY...................................................................................................................625 ASSEMBLY......................................................................................................................626 CARRIER ROLLER ASSEMBLY...........................................................................................................628 REMOVAL.......................................................................................................................628 INSTALLATION..................................................................................................................628 DISASSEMBLY...................................................................................................................629 ASSEMBLY......................................................................................................................630 TRACK SHOE ASSEMBLY...............................................................................................................631 CHECKING BEFORE REMOVAL.......................................................................................................631 REMOVAL (NORMAL)..............................................................................................................631 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME)........................................................................632 INSTALLATION..................................................................................................................633 TRACK SHOE........................................................................................................................634 OVERALL DISASSEMBLY...........................................................................................................634 OVERALL ASSEMBLY..............................................................................................................639 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS..................................................................................653 ONE LINK..........................................................................................................................654 FIELD DISASSEMBLY.............................................................................................................654 FIELD ASSEMBLY................................................................................................................655 PIVOT SHAFT ASSEMBLY..............................................................................................................661 REMOVAL.......................................................................................................................661 INSTALLATION..................................................................................................................661 EQUALIZER BAR ASSEMBLY............................................................................................................662 REMOVAL.......................................................................................................................662 INSTALLATION..................................................................................................................663 EQUALIZER BAR SIDE BUSHING........................................................................................................664 REMOVAL.......................................................................................................................664 INSTALLATION..................................................................................................................664 SEGMENT TEETH.....................................................................................................................665 REMOVAL.......................................................................................................................665 INSTALLATION..................................................................................................................665 HSS, WORK EQUIPMENT PUMP ASSEMBLY.................................................................................................666 REMOVAL.......................................................................................................................666 INSTALLATION..................................................................................................................666 DISASSEMBLY...................................................................................................................667 ASSEMBLY......................................................................................................................672 PPC PUMP ASSEMBLY.................................................................................................................681 REMOVAL.......................................................................................................................681 INSTALLATION..................................................................................................................681 MAIN CONTROL VALVE ASSEMBLY.......................................................................................................682 REMOVAL (2-SPOOL: BLADE LIFT +TILT)...........................................................................................682 INSTALLATION (2-SPOOL: BLADE LIFT +TILT)......................................................................................682 REMOVAL (3-SPOOL: BLADE LIFT + TILT + STEERING)...............................................................................683 INSTALLATION (3-SPOOL: BLADE LIFT +TILT +STEERING)............................................................................683 DISASSEMBLY (3-SPOOL VALVE)...................................................................................................684 ASSEMBLY (3-SPOOL VALVE)......................................................................................................686 MAIN RELIEF VALVE.................................................................................................................688 REMOVAL.......................................................................................................................688 INSTALLATION..................................................................................................................688 PPC VALVE ASSEMBLY................................................................................................................689 REMOVAL (FOR WORK EQUIPMENT)..................................................................................................689 INSTALLATION (FOR WORK EQUIPMENT).............................................................................................689 REMOVAL (FOR STEERING)........................................................................................................690 INSTALLATION (FOR STEERING)...................................................................................................691 DISASSEMBLY (FOR WORK EQUIPMENT)..............................................................................................692 ASSEMBLY (FOR WORK EQUIPMENT).................................................................................................693 DISASSEMBLY (FOR STEERING)....................................................................................................694 ASSEMBLY......................................................................................................................695 PPC CHARGE RELIEF VALVE ASSEMBLY..................................................................................................696 REMOVAL.......................................................................................................................696 INSTALLATION..................................................................................................................696 DISASSEMBLY...................................................................................................................697 ASSEMBLY......................................................................................................................697 SUCTION VALVE ASSEMBLY............................................................................................................698 REMOVAL.......................................................................................................................698 INSTALLATION..................................................................................................................698 BLADE LIFT CYLINDER ASSEMBLY......................................................................................................699 REMOVAL.......................................................................................................................699 INSTALLATION..................................................................................................................699 BLADE TILT CYLINDER ASSEMBLY......................................................................................................700 REMOVAL.......................................................................................................................700 INSTALLATION..................................................................................................................700 HYDRAULIC CYLINDER ASSEMBLY.......................................................................................................701 DISASSEMBLY...................................................................................................................701 ASSEMBLY......................................................................................................................703 WORK EQUIPMENT ASSEMBLY...........................................................................................................706 REMOVAL.......................................................................................................................706 INSTALLATION..................................................................................................................707 DISASSEMBLY...................................................................................................................708 ASSEMBLY......................................................................................................................710 RIPPER VALVE ASSEMBLY (IF EQUIPPED)...............................................................................................712 DISASSEMBLY...................................................................................................................712 ASSEMBLY......................................................................................................................713 ROPS GUARD .......................................................................................................................714 REMOVAL.......................................................................................................................714 INSTALLATION..................................................................................................................714 OPERATOR'S CAB ASSEMBLY...........................................................................................................715 REMOVAL.......................................................................................................................715 INSTALLATION..................................................................................................................716 DASHBOARD ASSEMBLY................................................................................................................717 REMOVAL.......................................................................................................................717 INSTALLATION..................................................................................................................717 MONITOR ASSEMBLY..................................................................................................................718 REMOVAL.......................................................................................................................718 INSTALLATION..................................................................................................................718 FLOOR FRAME ASSEMBLY..............................................................................................................719 REMOVAL.......................................................................................................................719 INSTALLATION..................................................................................................................723 40 MAINTENANCE STANDARD...............................................................................................................724 ENGINE MOUNT......................................................................................................................725 POWER TRAIN UNIT MOUNT............................................................................................................726 DAMPER, UNIVERSAL JOINT...........................................................................................................727 TORQUE CONVERTER, PTO.............................................................................................................728 TRANSMISSION......................................................................................................................730 TRANSMISSION CONTROL VALVE........................................................................................................732 MAIN RELIEF VALVE.................................................................................................................733 BEVEL GEAR SHAFT, HSS STEERING, BRAKE.............................................................................................734 BEVEL GEAR SHAFT, HSS BRAKE VALVE.................................................................................................737 POWER TRAIN, LUBRICATION PUMP.....................................................................................................738 PPC PUMP..........................................................................................................................739 PPC VALVE.........................................................................................................................740 PPC CHARGE VALVE..................................................................................................................744 FINAL DRIVE.......................................................................................................................745 HULL FRAME........................................................................................................................747 TRACK FRAME, RECOIL SPRING........................................................................................................748 IDLER.............................................................................................................................749 TRACK ROLLER......................................................................................................................751 CARRIER ROLLER....................................................................................................................753 SPROCKET TOOTH PROFILE............................................................................................................754 TRACK SHOE (DRY TYPE).............................................................................................................755 TRACK SHOE (LUBRICATED TYPE)......................................................................................................757 SUSPENSION........................................................................................................................759 HYDRAULIC, HSS PUMP...............................................................................................................761 HSS MOTOR.........................................................................................................................762 MAIN CONTROL VALVE................................................................................................................763 WORK EQUIPMENT CYLINDER...........................................................................................................768 WORK EQUIPMENT....................................................................................................................770 CUTTING EDGE, END BIT.............................................................................................................776 RIPPER............................................................................................................................777 90 OTHERS.............................................................................................................................778 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM.............................................................................................779 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.............................................................................780 ELECTRICAL CIRCUIT DIAGRAM (1/3)..................................................................................................781 ELECTRICAL CIRCUIT DIAGRAM (2/3)..................................................................................................782 ELECTRICAL CIRCUIT DIAGRAM (3/3)..................................................................................................783 ELECTRICAL CIRCUIT DIAGRAM (INSIDE CAB)...........................................................................................784
DESCRIPTION:
KOMATSU D65EX-12 D65PX-12 SHOP MANUAL SEBM027202 – PDF DOWNLOAD
FOREWORD
GENERAL
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity.
This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components
STRUCTURE AND FUNCTION
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” to “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY
This section explains the order to be followed when removing, installing, disassembling or assembling each component, as well as precautions to be taken for these operations.
MAINTENANCE STANDARD
This section gives the judgement standards when inspecting 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 30/12/24
