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Komatsu D66S-1 Crawler Loader Dozer Shovel Shop Manual SEBM0142A10 – PDF DOWNLOAD
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Komatsu D66S-1 Crawler LoaderDozer Shovel Shop Manual SEBM0142A10
MACHINE MODEL SERIAL No.
D66S-1 1001 and up
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Description
Komatsu D66S-1 Crawler LoaderDozer Shovel Shop Manual SEBM0142A10
FILE DETAILS:
Komatsu D66S-1 Crawler LoaderDozer Shovel Shop Manual SEBM0142A10
Brands: Komatsu
Equipment Type: Crawler Loader/Dozer Shovel
Manuals Type: Shop Manual
Machine Model: D66S-1
Serial Number: 1001 and up
Book Code: SEBM0142A10
Language: English
Pages: 626
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D66S-1 Crawler LoaderDozer Shovel Shop Manual SEBM0142A10
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.
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.
TABLE OF CONTENTS:
Komatsu D66S-1 Crawler LoaderDozer Shovel Shop Manual SEBM0142A10
COVER........................................................................................................................................................................................................................... 1
CONTENTS........................................................................................................................................................................................................................ 2
01 GENERAL...................................................................................................................................................................................................................... 35
GENERAL VIEW................................................................................................................................................................................................................ 36
ASSEMBLY DRAWING............................................................................................................................................................................................................ 37
SPECIFICATIONS.............................................................................................................................................................................................................. 38
ENGINE ASSEMBLY DRAWING..................................................................................................................................................................................................... 40
ENGINE SPECIFICATIONS....................................................................................................................................................................................................... 44
WEIGHT TABLE................................................................................................................................................................................................................ 45
TABLE OF OIL AND COOLANT QUANTITIES......................................................................................................................................................................................... 46
OUTLINE..................................................................................................................................................................................................................... 47
LAYOUT OF LIST ELECTRONIC CONTROL, MONITOR, SENSORS, ACTUATORS AND CONTROLLER............................................................................................................................................... 49
MONITORING SYSTEM........................................................................................................................................................................................................... 50
10 ENGINE....................................................................................................................................................................................................................... 51
11 STRUCTURE AND FUNCTION................................................................................................................................................................................................... 51
ENGINE MOUNT............................................................................................................................................................................................................ 52
RADIATOR AND COOLER..................................................................................................................................................................................................... 53
FUEL TANK AND PIPING.................................................................................................................................................................................................... 54
ENGINE CONTROL.......................................................................................................................................................................................................... 55
12 TESTING AND ADJUSTING.................................................................................................................................................................................................... 56
STANDARD VALUE TABLE.................................................................................................................................................................................................... 57
TOOL LIST FOR TESTING AND ADJUSTING..................................................................................................................................................................................... 58
ADJUSTING VALVE CLEARANCE............................................................................................................................................................................................... 59
MEASURING COMPRESSION PRESSURE.......................................................................................................................................................................................... 60
TESTING AND ADJUSTING FUEL INJECTION TIMING............................................................................................................................................................................. 61
TESTING AND ADJUSTING FAN BELT TENSION.................................................................................................................................................................................. 63
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE........................................................................................................................................................................... 64
MEASURING BLOW-BY PRESSURE.............................................................................................................................................................................................. 65
13 DISASSEMBLY AND ASSEMBLY................................................................................................................................................................................................. 66
STARTING MOTOR ASSEMBLY................................................................................................................................................................................................. 67
REMOVAL............................................................................................................................................................................................................. 67
INSTALLATION........................................................................................................................................................................................................ 67
ALTERNATOR ASSEMBLY..................................................................................................................................................................................................... 68
REMOVAL............................................................................................................................................................................................................. 68
INSTALLATION........................................................................................................................................................................................................ 68
FUEL INJECTION PUMP ASSEMBLY............................................................................................................................................................................................ 69
REMOVAL............................................................................................................................................................................................................. 69
INSTALLATION........................................................................................................................................................................................................ 69
WATER PUMP ASSEMBLY..................................................................................................................................................................................................... 70
REMOVAL............................................................................................................................................................................................................. 70
INSTALLATION........................................................................................................................................................................................................ 70
NOZZLE HOLDER ASSEMBLY.................................................................................................................................................................................................. 71
REMOVAL............................................................................................................................................................................................................. 71
INSTALLATION........................................................................................................................................................................................................ 71
CYLINDER HEAD ASSEMBLY.................................................................................................................................................................................................. 72
REMOVAL............................................................................................................................................................................................................. 72
INSTALLATION........................................................................................................................................................................................................ 79
TURBOCHARGER ASSEMBLY................................................................................................................................................................................................... 88
REMOVAL............................................................................................................................................................................................................. 88
INSTALLATION........................................................................................................................................................................................................ 88
AFTER-COOLER CORE ASSEMBLY.............................................................................................................................................................................................. 89
REMOVAL............................................................................................................................................................................................................. 89
INSTALLATION........................................................................................................................................................................................................ 90
RADIATOR ASSEMBLY....................................................................................................................................................................................................... 91
REMOVAL............................................................................................................................................................................................................. 91
INSTALLATION........................................................................................................................................................................................................ 91
ENGINE OIL COOLER ASSEMBLY.............................................................................................................................................................................................. 93
REMOVAL............................................................................................................................................................................................................. 93
INSTALLATION........................................................................................................................................................................................................ 93
ENGINE, RADIATOR ASSEMBLY............................................................................................................................................................................................... 94
REMOVAL............................................................................................................................................................................................................. 94
INSTALLATION........................................................................................................................................................................................................ 95
ENGINE ASSEMBLY......................................................................................................................................................................................................... 96
REMOVAL............................................................................................................................................................................................................. 96
INSTALLATION........................................................................................................................................................................................................ 96
HOOD ASSEMBLY (SERIAL NO.1001-1399)..................................................................................................................................................................................... 97
OPENING............................................................................................................................................................................................................. 97
CLOSING............................................................................................................................................................................................................. 97
HOOD ASSEMBLY (SERIAL NO.1400 AND UP)................................................................................................................................................................................... 98
REMOVAL............................................................................................................................................................................................................. 98
INSTALLATION........................................................................................................................................................................................................ 98
HST OIL COOLER ASSEMBLY (SERIAL NO.1001-1399)........................................................................................................................................................................... 99
REMOVAL............................................................................................................................................................................................................. 99
INSTALLATION........................................................................................................................................................................................................ 99
HST OIL COOLER ASSEMBLY (SERIAL NO.1400 AND UP).........................................................................................................................................................................100
REMOVAL.............................................................................................................................................................................................................100
INSTALLATION........................................................................................................................................................................................................100
20 POWER TRAIN..................................................................................................................................................................................................................101
21 STRUCTURE AND FUNCTION...................................................................................................................................................................................................101
GENERAL.................................................................................................................................................................................................................102
POWER TRAIN HYDRAULIC SYSTEM............................................................................................................................................................................................104
DAMPER..................................................................................................................................................................................................................108
DRIVE SHAFT (INPUT, OUTPUT).............................................................................................................................................................................................110
TORQUE SPLITTER.........................................................................................................................................................................................................111
HST (HYDROSTATIC TRANSMISSION)..........................................................................................................................................................................................113
HYDROSTATIC TRANSMISSION PIPING.........................................................................................................................................................................................115
SPEED CONTROL...........................................................................................................................................................................................................117
HYDROSTATIC TRANSMISSION OIL CIRCUIT DIAGRAM............................................................................................................................................................................118
COMPONENTS OF HST (SERIAL NO.1001-1399).................................................................................................................................................................................124
HST PUMP GROUP (SERIAL NO.1001-1399)....................................................................................................................................................................................125
COMPONENTS OF HST (SERIAL NO.1400 AND UP)...............................................................................................................................................................................128
HST PUMP GROUP (SERIAL NO.1400 AND UP)..................................................................................................................................................................................129
HST MOTOR GROUP.........................................................................................................................................................................................................158
HST CHARGING PUMP AND HST SERVO PUMP....................................................................................................................................................................................165
HST FILTER..............................................................................................................................................................................................................168
CHARGE OIL FILTER BYPASS VALVE AND CHARGE OIL SAFETY VALVE..............................................................................................................................................................169
HST TANK................................................................................................................................................................................................................172
STEERING CONTROL........................................................................................................................................................................................................173
BRAKE CONTROL...........................................................................................................................................................................................................174
BRAKE AND BRAKE CONTROL VALVE...........................................................................................................................................................................................175
FINAL DRIVE.............................................................................................................................................................................................................184
22 TESTING AND ADJUSTING....................................................................................................................................................................................................186
STANDARD VALUE TABLE....................................................................................................................................................................................................187
TESTING AND ADJUSTING...................................................................................................................................................................................................189
BLEEDING AIR FROM HST BRAKE CIRCUIT.................................................................................................................................................................................189
TESTING AND ADJUSTING HYDRAULIC PRESSURE............................................................................................................................................................................190
MEASURING OIL TEMPERATURE...........................................................................................................................................................................................192
MEASURING OPERATING FORCE...........................................................................................................................................................................................193
MEASURING AND ADJUSTING TRAVEL......................................................................................................................................................................................194
PROCEDURE FOR ADJUSTMENT OF TRAVEL DEVIATION............................................................................................................................................................................199
TROUBLESHOOTING.........................................................................................................................................................................................................205
1.OUTLINE OF TROUBLESHOOTING FOR HST AND HST ELECTRONIC CONTROL SYSTEM..............................................................................................................................................206
2.HST TROUBLESHOOTING...............................................................................................................................................................................................209
CONTENTS........................................................................................................................................................................................................209
1.INTRODUCTION..............................................................................................................................................................................................210
2.ASSUMPTIONS WHEN TROUBLESHOOTING..........................................................................................................................................................................210
3.PRECAUTIONS REGARDING DIRT AND CONTAMINATION IN OIL.......................................................................................................................................................210
4.TROUBLESHOOTING TOOLS AND REPLACEMENT PARTS FOR TROUBLESHOOTING...........................................................................................................................................210
5.PRECAUTIONS FOR UNIT EXCHANGE.............................................................................................................................................................................211
6.TROUBLESHOOTING...........................................................................................................................................................................................212
H-1 MACHINE DOES NOT MOVE FORWARD OR IN REVERSE.........................................................................................................................................................212
H-2 MACHINE MOVES IN ONE DIRECTION (FORWARD OR REVERSE) BUT NOT IN OTHER DIRECTION......................................................................................................................214
H-3 MACHINE MOVES EVEN WHEN SPEED CONTROL LEVER IS IN NEUTRAL...........................................................................................................................................215
H-4 MACHINE DEVIATES GRADUALLY..........................................................................................................................................................................215
H-5 MACHINE DEVIATES SHARPLY............................................................................................................................................................................218
H-6 TRACKS COUNTERROTATE................................................................................................................................................................................221
H-7 MACHINE MOVES IN OPPOSITE DIRECTION.................................................................................................................................................................221
H-7' WHEN STARTING ON LEVEL GROUND......................................................................................................................................................................222
H-8 MACHINE MOVES SUDDENLY WHEN STARTING................................................................................................................................................................222
H-9 WHEN MACHINE STARTS, FRONT OF MACHINE WAVERS SLIGHTLY...............................................................................................................................................223
H-10 EXCESSIVE TIME LAG WHEN STARTING...................................................................................................................................................................224
H-11 POOR ACCELERATION..................................................................................................................................................................................224
H-12 DIFFICULT TO TURN..................................................................................................................................................................................225
H-13 MACHINE TURNS SHARPLY INSTEAD OF GRADUALLY.........................................................................................................................................................226
H-14 MACHINE TURNS IN OPPOSITE DIRECTION................................................................................................................................................................226
H-15 MACHINE DOES NOT RETURN TO STRAIGHT LINE...........................................................................................................................................................226
H-16 MACHINE OVERSTEERS.................................................................................................................................................................................227
H-17 MACHINE DOES NOT SLOW DOWN SMOOTHLY................................................................................................................................................................228
H-18 MACHINE DEVIATES WHEN SLOWING DOWN.................................................................................................................................................................229
H-19 MACHINE CANNOT BE CONTROLLED ON DOWNHILL SLOPES....................................................................................................................................................230
H-20 MACHINE STOPS SUDDENLY.............................................................................................................................................................................230
H-21 MACHINE LACKS POWER (MACHINE CANNOT TRAVEL AT MAXIMUM SPEED.)......................................................................................................................................231
H-22 MACHINE LACKS POWER (ENGINE STALLS.)...............................................................................................................................................................232
H-23 EXCESSIVE NOISE FROM HST...........................................................................................................................................................................233
H-24 HST OIL TEMPERATURE RISES TOO HIGH.................................................................................................................................................................234
23 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................235
DAMPER ASSEMBLY.........................................................................................................................................................................................................236
REMOVAL.............................................................................................................................................................................................................236
INSTALLATION........................................................................................................................................................................................................237
TORQUE SPLITTER ASSEMBLY................................................................................................................................................................................................238
REMOVAL.............................................................................................................................................................................................................238
INSTALLATION........................................................................................................................................................................................................241
DISASSEMBLY.........................................................................................................................................................................................................244
ASSEMBLY............................................................................................................................................................................................................247
HST ASSEMBLY............................................................................................................................................................................................................250
REMOVAL.............................................................................................................................................................................................................250
INSTALLATION........................................................................................................................................................................................................254
HST UNIT................................................................................................................................................................................................................260
DISASSEMBLY.........................................................................................................................................................................................................260
ASSEMBLY............................................................................................................................................................................................................277
HST PUMP SERVO VALVE ASSEMBLY...........................................................................................................................................................................................332
REMOVAL.............................................................................................................................................................................................................332
INSTALLATION........................................................................................................................................................................................................332
ASSIST VALVE ASSEMBLY...................................................................................................................................................................................................333
REMOVAL.............................................................................................................................................................................................................333
INSTALLATION........................................................................................................................................................................................................334
DISASSEMBLY.........................................................................................................................................................................................................335
ASSEMBLY............................................................................................................................................................................................................337
NEUTRAL BYPASS VALVE ASSEMBLY...........................................................................................................................................................................................339
DISASSEMBLY.........................................................................................................................................................................................................339
ASSEMBLY............................................................................................................................................................................................................339
HST MOTOR SERVO VALVE ASSEMBLY..........................................................................................................................................................................................340
REMOVAL.............................................................................................................................................................................................................340
INSTALLATION........................................................................................................................................................................................................340
CHARGING, SERVO PUMP ASSEMBLY...........................................................................................................................................................................................341
REMOVAL.............................................................................................................................................................................................................341
INSTALLATION........................................................................................................................................................................................................341
CHARGE FILTER BYPASS VALVE ASSEMBLY.....................................................................................................................................................................................342
REMOVAL.............................................................................................................................................................................................................342
INSTALLATION........................................................................................................................................................................................................342
DISASSEMBLY.........................................................................................................................................................................................................343
ASSEMBLY............................................................................................................................................................................................................343
BRAKE CONTROL VALVE ASSEMBLY............................................................................................................................................................................................344
REMOVAL.............................................................................................................................................................................................................344
INSTALLATION........................................................................................................................................................................................................345
DISASSEMBLY.........................................................................................................................................................................................................346
ASSEMBLY............................................................................................................................................................................................................348
FINAL DRIVE ASSEMBLY....................................................................................................................................................................................................351
REMOVAL.............................................................................................................................................................................................................351
INSTALLATION........................................................................................................................................................................................................353
DISASSEMBLY.........................................................................................................................................................................................................355
ASSEMBLY............................................................................................................................................................................................................366
24 MAINTENANCE STANDARD.....................................................................................................................................................................................................374
DAMPER..................................................................................................................................................................................................................375
TORQUE SPLITTER.........................................................................................................................................................................................................376
CHARGING PUMP AND SERVO PUMP............................................................................................................................................................................................377
BYPASS VALVE FOR CHARGING FILTER........................................................................................................................................................................................378
BRAKE...................................................................................................................................................................................................................379
FINAL DRIVE.............................................................................................................................................................................................................380
30 UNDERCARRIAGE................................................................................................................................................................................................................382
31 STRUCTURE AND FUNCTION...................................................................................................................................................................................................382
TRACK GROUP.............................................................................................................................................................................................................383
RECOIL SPRING...........................................................................................................................................................................................................384
IDLER...................................................................................................................................................................................................................385
CARRIER ROLLER..........................................................................................................................................................................................................386
TRACK ROLLER............................................................................................................................................................................................................387
TRACK...................................................................................................................................................................................................................388
SUSPENSION..............................................................................................................................................................................................................389
33 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................391
TRACK FRAME ASSEMBLY....................................................................................................................................................................................................392
REMOVAL.............................................................................................................................................................................................................392
INSTALLATION........................................................................................................................................................................................................393
RECOIL SPRING ASSEMBLY..................................................................................................................................................................................................394
REMOVAL.............................................................................................................................................................................................................394
INSTALLATION........................................................................................................................................................................................................395
DISASSEMBLY.........................................................................................................................................................................................................396
ASSEMBLY............................................................................................................................................................................................................397
IDLER ASSEMBLY..........................................................................................................................................................................................................398
REMOVAL.............................................................................................................................................................................................................398
INSTALLATION........................................................................................................................................................................................................398
TRACK ROLLER ASSEMBLY...................................................................................................................................................................................................399
REMOVAL.............................................................................................................................................................................................................399
INSTALLATION........................................................................................................................................................................................................399
CARRIER ROLLER ASSEMBLY.................................................................................................................................................................................................400
REMOVAL.............................................................................................................................................................................................................400
INSTALLATION........................................................................................................................................................................................................400
TRACK SHOE ASSEMBLY.....................................................................................................................................................................................................401
REMOVAL.............................................................................................................................................................................................................401
INSTALLATION........................................................................................................................................................................................................403
ADJUSTING TENSION...................................................................................................................................................................................................405
PIVOT SHAFT ASSEMBLY....................................................................................................................................................................................................406
REMOVAL.............................................................................................................................................................................................................406
INSTALLATION........................................................................................................................................................................................................407
34 MAINTENANCE STANDARD.....................................................................................................................................................................................................408
TRACK FRAME.............................................................................................................................................................................................................409
RECOIL SPRING...........................................................................................................................................................................................................410
IDLER...................................................................................................................................................................................................................411
TRACK ROLLER............................................................................................................................................................................................................413
CARRIER ROLLER..........................................................................................................................................................................................................415
MEASURING PROCEDURE OF ROLLERS..........................................................................................................................................................................................416
TRACK SHOE..............................................................................................................................................................................................................418
MEASURING PROCEDURE OF TRACK............................................................................................................................................................................................420
SUSPENSION..............................................................................................................................................................................................................422
60 HYDRAULIC SYSTEM.............................................................................................................................................................................................................424
61 STRUCTURE AND FUNCTION...................................................................................................................................................................................................424
GENERAL.................................................................................................................................................................................................................425
HYDRAULIC CIRCUIT SYSTEM................................................................................................................................................................................................427
HYDRAULIC CONTROL.......................................................................................................................................................................................................429
HYDRAULIC AND UNLOADER PUMPS............................................................................................................................................................................................430
BUCKET CONTROL VALVE....................................................................................................................................................................................................431
UNLOADER VALVE..........................................................................................................................................................................................................436
HYDRAULIC TANK..........................................................................................................................................................................................................439
HYDRAULIC CYLINDER......................................................................................................................................................................................................440
62 TESTING AND ADJUSTING....................................................................................................................................................................................................441
STANDARD VALUE TABLE....................................................................................................................................................................................................442
TESTING AND ADJUSTING HYDRAULIC PRESSURE................................................................................................................................................................................443
MEASURING HYDRAULIC OIL TEMPERATURE.....................................................................................................................................................................................444
TESTING AND ADJUSTING TRAVEL AND OPERATING FORCE OF CONTROL LEVER.......................................................................................................................................................444
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT.............................................................................................................................................................................445
ADJUSTING ELECTRIC POSITIONER...........................................................................................................................................................................................446
63 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................447
MAIN CONTROL VALVE, PLATE ASSEMBLY (SERIAL NO.1001-1399)................................................................................................................................................................448
REMOVAL.............................................................................................................................................................................................................448
INSTALLATION........................................................................................................................................................................................................449
MAIN CONTROL VALVE, PLATE ASSEMBLY (SERIAL NO.1400 AND UP)..............................................................................................................................................................450
REMOVAL.............................................................................................................................................................................................................450
INSTALLATION........................................................................................................................................................................................................451
MAIN CONTROL VALVE ASSEMBLY.............................................................................................................................................................................................452
REMOVAL.............................................................................................................................................................................................................452
INSTALLATION........................................................................................................................................................................................................454
RIPPER CONTROL VALVE ASSEMBLY...........................................................................................................................................................................................455
REMOVAL.............................................................................................................................................................................................................455
INSTALLATION........................................................................................................................................................................................................455
MAIN CONTROL VALVE ASSEMBLY.............................................................................................................................................................................................456
DISASSEMBLY.........................................................................................................................................................................................................456
ASSEMBLY............................................................................................................................................................................................................458
UNLOADER VALVE ASSEMBLY.................................................................................................................................................................................................460
REMOVAL.............................................................................................................................................................................................................460
INSTALLATION........................................................................................................................................................................................................460
DISASSEMBLY.........................................................................................................................................................................................................462
ASSEMBLY............................................................................................................................................................................................................463
HYDRAULIC PUMP, UNLOADER PUMP ASSEMBLY..................................................................................................................................................................................464
REMOVAL.............................................................................................................................................................................................................464
INSTALLATION........................................................................................................................................................................................................464
DUMP CYLINDER ASSEMBLY..................................................................................................................................................................................................465
REMOVAL.............................................................................................................................................................................................................465
INSTALLATION........................................................................................................................................................................................................465
LIFT CYLINDER ASSEMBLY..................................................................................................................................................................................................466
REMOVAL.............................................................................................................................................................................................................466
INSTALLATION........................................................................................................................................................................................................467
HYDRAULIC CYLINDER ASSEMBLY.............................................................................................................................................................................................468
DISASSEMBLY.........................................................................................................................................................................................................468
ASSEMBLY............................................................................................................................................................................................................470
64 MAINTENANCE STANDARD.....................................................................................................................................................................................................473
HYDRAULIC CONTROL VALVE.................................................................................................................................................................................................474
UNLOADER VALVE..........................................................................................................................................................................................................476
HYDRAULIC AND UNLOADER PUMPS............................................................................................................................................................................................478
DUMP CYLINDER...........................................................................................................................................................................................................479
LIFT CYLINDER...........................................................................................................................................................................................................480
70 WORK EQUIPMENT...............................................................................................................................................................................................................481
71 STRUCTURE AND FUNCTION...................................................................................................................................................................................................481
BUCKET LINK.............................................................................................................................................................................................................482
BUCKET CONTROL..........................................................................................................................................................................................................484
BUCKET..................................................................................................................................................................................................................486
73 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................487
WORK EQUIPMENT ASSEMBLY.................................................................................................................................................................................................488
REMOVAL.............................................................................................................................................................................................................488
INSTALLATION........................................................................................................................................................................................................489
74 MAINTENANCE STANDARD.....................................................................................................................................................................................................490
BUCKET LINK.............................................................................................................................................................................................................491
BUCKET..................................................................................................................................................................................................................493
80 ELECTRIC AND ELECTRONIC SYSTEM...............................................................................................................................................................................................494
81 STRUCTURE AND FUNCTION...................................................................................................................................................................................................494
OUTLINE OF ELECTRIC AND ELECTRONIC SYSTEMS..............................................................................................................................................................................495
HST CONTROL SYSTEM......................................................................................................................................................................................................497
SELF-CHECK FUNCTION OF HST CONTROL SYSTEM...............................................................................................................................................................................501
HST CONTROLLER..........................................................................................................................................................................................................502
POTENTIOMETER...........................................................................................................................................................................................................503
ENGINE SPEED SENSOR.....................................................................................................................................................................................................504
ELECTRONIC MONITORING SYSTEM............................................................................................................................................................................................506
WIRING DIAGRAM FOR CAB..................................................................................................................................................................................................519
ELECTRIC CIRCUIT........................................................................................................................................................................................................520
82 TESTING AND ADJUSTING....................................................................................................................................................................................................521
OUTLINE OF TROUBLESHOOTING..............................................................................................................................................................................................522
WAY OF USING TROUBLESHOOTING TABLES.....................................................................................................................................................................................523
PRECAUTIONS WHEN TROUBLESHOOTING........................................................................................................................................................................................524
ELECTRICAL AND ELECTRONIC EQUIPMENT FOR D66S-1..........................................................................................................................................................................527
TROUBLESHOOTING FOR MONITOR PANEL.......................................................................................................................................................................................534
1.CHECK THE FOLLOWS BEFORE STARTING TROUBLESHOOTING.................................................................................................................................................................534
2.WIRING DIAGRAM AS TO MONITOR PANEL................................................................................................................................................................................535
3.CONNECTOR NUMBERS FOR MONITOR PANEL...............................................................................................................................................................................536
4.METHOD OF REMOVING MONITOR PANEL BOX..............................................................................................................................................................................539
5.TROUBLESHOOTING CHART FOR MONITOR PANEL...........................................................................................................................................................................540
6.TROUBLESHOOTING...................................................................................................................................................................................................541
TROUBLESHOOTING OF HST ELECTRONIC CONTROL SYSTEM........................................................................................................................................................................566
1.OUTLINE...........................................................................................................................................................................................................566
2.SELF-CHECK FUNCTION BY MONITOR PANEL..............................................................................................................................................................................569
3.TROUBLESHOOTING OF HST ELECTRONIC CONTROL SYSTEM BY USING ATESTER.................................................................................................................................................573
CONTENTS........................................................................................................................................................................................................573
1.TROUBLESHOOTING TOOLS.....................................................................................................................................................................................574
2.TROUBLESHOOTING ..........................................................................................................................................................................................576
A.IN CASE THAT SELF-CHECK FUNCTION ON THE MONITOR PANEL ("HST ELECTRONIC SYSTEM MONITOR 1","HST ELECTRONIC SYSTEM MONITOR 2","HST OIL PRESSURE MONITOR","WARNING LAMP","ALARM BUZZER") IS DISPLAYED.....576
T-1 DROP IN HST CHANGE PRESSURE.....................................................................................................................................................................576
T-2 NO SUPPLY OF ELECTRIC POWER TO HST CONTROLLER...................................................................................................................................................578
T-3 BREAKDOWN IN SPEED CONTROL LEVER SYSTEM.........................................................................................................................................................581
T-4 BREAKDOWN IN PEDAL SYSTEM.......................................................................................................................................................................587
T-5 BREAKDOWN IN HST SERVO SYSTEM (SOLENOID VALVE)..................................................................................................................................................589
T-6 BREAKDOWN IN THE FUEL CONTROL LEVER AND ENGINE SPEED SENSOR.....................................................................................................................................591
T-7 BREAKDOWN IN STRAIGHT TRAVEL COMPENSATION SYSTEM................................................................................................................................................595
B.IN CASE THAT DISPLAY OF MONITOR PANEL IS NORMAL, BUT MACHINE MOVEMENT IS ABNORMAL.....................................................................................................................597
T-8 MACHINE DOES NOT MOVE EITHER FORWARD OR IN REVERSE..............................................................................................................................................597
T-9 EITHER FORWARD OR REVERSE WORKS.................................................................................................................................................................601
T-10 MACHINE STOPS WHEN TRAVELING WITH NO LOAD......................................................................................................................................................604
T-11 MACHINE TRAVELS STRAIGHT, BUT THERE IS A PROBLEM WITH MACHINE SPEED............................................................................................................................607
T-12 WHILE TRAVELING, ONE SIDE STOPS MOVING.........................................................................................................................................................608
T-13 WHILE TRAVELING, ONE SIDE IS SLOWER OR FASTER THAN THE OTHER (MACHINE DEVIATES)................................................................................................................610
HOW TO INSTALL THE POTENTIOMETER........................................................................................................................................................................................611
83 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................613
ELECTRONIC CONTROLLER ASSEMBLY, MONITOR ASSEMBLY........................................................................................................................................................................614
REMOVAL.............................................................................................................................................................................................................614
INSTALLATION........................................................................................................................................................................................................616
90 OTHERS.......................................................................................................................................................................................................................618
91 STRUCTURE AND FUNCTION...................................................................................................................................................................................................618
ROPS CAB................................................................................................................................................................................................................619
AIR CONDITIONER ASSEMBLY................................................................................................................................................................................................620
AIR CONDITIONER PIPING..................................................................................................................................................................................................621
93 DISASSEMBLY AND ASSEMBLY.................................................................................................................................................................................................622
OPERATOR'S CAB, FRAME ASSEMBLY (SERIAL NO.1001-1399)....................................................................................................................................................................623
REMOVAL.............................................................................................................................................................................................................623
INSTALLATION........................................................................................................................................................................................................624
OPERATOR'S CAB, FRAME ASSEMBLY (SERIAL NO.1400 AND UP)..................................................................................................................................................................625
REMOVAL.............................................................................................................................................................................................................625
INSTALLATION........................................................................................................................................................................................................626
KOMATSU D66S-1 CRAWLER LOADER DOZER SHOVEL SHOP MANUAL SEBM0142A10 – PDF DOWNLOAD:
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