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Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Bulldozer (60001 and up) Shop Manual PDF DOWNLOA
Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Bulldozer (60001 and up) Shop Manual
FILE DETAILS:
Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Bulldozer (60001 and up) Shop Manual
File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Product Code : SEBM001922
Total Pages : 1227
DESCRIPTION:
Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Bulldozer (60001 and up) Shop Manual
FOREWORD:
GENERAL:
This shop manual has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to full effect at every opportunity. This shop manual mainly contains the necessary technical information for operations performed in a service workshop. For ease of understanding, the manual is divided into the following chapters; these chapters are further divided into the each main group of components.
STRUCTURE AND FUNCTION:
This section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting.
In addition, this section may contain hydraulic circuit diagrams, electric circuit diagrams, and maintenance standards.
TESTING AND ADJUSTING:
This section explains checks to be made before and after performing repairs, as well as adjustments to be made at completion of the checks and repairs. Troubleshooting charts correlating “Problems” with “Causes” are also included in this section.
DISASSEMBLY AND ASSEMBLY:
This section explains the procedures for removing, installing, disassembling and assembling each component, as well as precautions for them.
MAINTENANCE STANDARD:
This section gives the judgment standards for inspection of disassembled parts. The contents of this section may be described in STRUCTURE AND FUNCTION.
OTHERS:
This section mainly gives hydraulic circuit diagrams and electric circuit diagrams. In addition, this section may give the specifications of attachments and options together.
TABLE OF CONTENTS:
Komatsu D65E-12, D65P-12, D65EX-12, D65PX-12 Bulldozer (60001 and up) Shop Manual
COVER............................................................................................................. 1 CONTENTS.......................................................................................................... 2 01 GENERAL........................................................................................................ 28 GENERAL ASSEMBLY DRAWING...................................................................................... 29 SPECIFICATIONS................................................................................................ 33 WEIGHT TABLE.................................................................................................. 49 TABLE OF FUEL, COOLANT AND LUBRICANTS......................................................................... 55 10 STRUCTURE AND FUNCTION......................................................................................... 57 RADIATOR,OIL COOLER........................................................................................... 58 ENGINE CONTROL................................................................................................ 60 POWER TRAIN SYSTEM............................................................................................ 63 POWER TRAIN SKELETON.......................................................................................... 64 POWER TRAIN UNIT.............................................................................................. 67 POWER TRAIN HYDRAULIC PIPING DIAGRAM.......................................................................... 69 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM......................................................................... 73 POWER TRAIN HYDRAULIC SYSTEM DIAGRAM.......................................................................... 74 DAMPER,UNIVERSAL JOINT........................................................................................ 78 TORQUE CONVERTER AND PTO...................................................................................... 80 TRANSMISSION CONTROL.......................................................................................... 82 TRANSMISSION.................................................................................................. 85 TRANSMISSION CONTROL VALVE.................................................................................... 94 MAIN RELIEF VALVE............................................................................................. 103 LUBRICATION RELIEF VALVE...................................................................................... 105 STEERING,BRAKE CONTROL........................................................................................ 106 BEVEL GEAR SHAFT, STEERING CLUTCH,STEERING BRAKE (D65E,P-12).................................................. 108 STEERING CONTROL VALVE (D65E,P-12)............................................................................ 121 STEERING BRAKE VALVE (D65E,P-12).............................................................................. 128 REDUCING VALVE................................................................................................ 132 STEERING AND BRAKE CONTROL (D65EX,PX-12)...................................................................... 134 BEVEL GEAR SHAFT, HSS STEERING AND BRAKE (D65EX,PX-12)........................................................ 137 BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)............................................................... 158 SCAVENGING PUMP STRAINER...................................................................................... 162 POWER TRAIN OIL STRAINER...................................................................................... 163 POWER TRAIN OIL FILTER........................................................................................ 164 FINAL DRIVE................................................................................................... 165 MAIN FRAME.................................................................................................... 168 TRACK FRAME................................................................................................... 169 RECOIL SPRING................................................................................................. 171 SUSPENSION.................................................................................................... 173 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM....................................................................... 177 ANGLEDOZER................................................................................................ 177 STRAIGHT TILTDOZER........................................................................................ 179 POWER PITCH DOZER......................................................................................... 181 RIPPER.................................................................................................... 183 PPC CONTROL PIPING DIAGRAM.................................................................................... 184 WORK EQUIPMENT CONTROL........................................................................................ 189 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................... 191 WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM....................................................................... 192 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM......................................................... 199 STEERING AND WORK EQUIPMENT HYDRAULIC SYSTEM DIAGRAM.......................................................... 200 HYDRAULIC TANK AND FILTER..................................................................................... 207 HYDRAULIC,HSS PUMP (D65EX,PX-12).............................................................................. 211 PPC VALVE (FOR STEERING) (D65EX,PX-12)........................................................................ 226 PPC VALVE (FOR STEERING) (D65E,P-12).......................................................................... 233 PPC VALVE (FOR BLADE LIFT, TILT AND RIPPER)................................................................... 237 PPC CHARGE VALVE.............................................................................................. 250 PPC LOCK VALVE................................................................................................ 252 MAIN CONTROL VALVE (2-SPOOL VALVE) (D65E,P-12)................................................................ 253 MAIN CONTROL VALVE (2-SPOOL VALVE) (D65EX,PX-12).............................................................. 291 POWER PITCH SELECTOR VALVE.................................................................................... 343 HSS MOTOR..................................................................................................... 346 OPERATION OF STEERING, WORK EQUIPMENT CONTROL CIRCUIT......................................................... 351 SUCTION VALVE................................................................................................. 359 PISTON VALVE.................................................................................................. 363 WORK EQUIPMENT................................................................................................ 364 ELECTRICAL CIRCUIT DIAGRAM.................................................................................... 368 ENGINE CONTROL................................................................................................ 380 MACHINE MONITOR SYSTEM........................................................................................ 381 SENSORS....................................................................................................... 385 20 TESTING AND ADJUSTING.......................................................................................... 388 STANDARD VALUE TABLE FOR ENGINE............................................................................... 389 STANDARD VALUE TABLE FOR CHASSIS.............................................................................. 397 STANDARD VALUE TABLE FOR ELECTRICAL SYSTEM.................................................................... 426 TOOL LIST FOR TESTING AND ADJUSTING........................................................................... 429 ADJUSTING VALVE CLEARANCE..................................................................................... 431 MEASURING COMPRESSION PRESSURE................................................................................ 432 MEASURING BLOWBY.............................................................................................. 433 ADJUSTING FULE INJECTION TIMING............................................................................... 434 MEASURING EXHAUST COLOR....................................................................................... 436 MEASURING BOOST PRESSURE...................................................................................... 437 MEASURING EXHAUST TEMPERATURE (D65P,EX,PX-12)................................................................. 438 MEASURING ENGINE OIL PRESSURE................................................................................. 439 MEASURING ENGINE SPEED........................................................................................ 439 TESTING FAN BELT TENSION...................................................................................... 440 MEASURING SPEED AT TORQUE CONVERTER STALL..................................................................... 441 ADJUSTING FULE CONTROL LINKAGE................................................................................ 442 ADJUSTING STEERING AND DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LEVER LINKAGE (D65E,P).............. 448 ADJUSTING DIRECTIONAL LEVER, GEAR SHIFT LEVER, PARKING BRAKE LINKAGE (D65EX,PX)............................... 455 ADJUSTING BRAKE PEDAL LINKAGE................................................................................. 461 D65E,P.................................................................................................... 461 D65EX,PX.................................................................................................. 463 ADJUSTING WORK EQUIPMENT CONTROL LINKAGE...................................................................... 464 ADJUSTING STRAIGHT TILTDOZER.................................................................................. 466 ADJUSTING PPC VALVE........................................................................................... 468 MEASURING POWER TRAIN OIL PRESSURE............................................................................ 469 D65E,P.................................................................................................... 469 D65EX,PX.................................................................................................. 476 TESTING AND ADJUSTING WORK EQUIPMENT HYDRAULIC PRESSURE (D65E,P).............................................. 483 TESTING AND ADJUSTING WORK EQUIPMENT, STEERING HYDRAULIC PRESSURE (D65EX,PX).................................. 484 TESTING AND ADJUSTING CONTROL CIRCUIT PRESSURE................................................................ 486 MEASURING OUTPUT PRESSURE OF PPC VALVE........................................................................ 488 MEASURING OIL LEAKAGE FROM HSS MOTOR (D65EX,PX)............................................................... 490 MEASURING LEAKAGE INSIDE CYLINDER............................................................................. 490 BLEEDING AIR FROM HYDRAULIC CYLINDER.......................................................................... 491 RELEASING REMAINING PRESSURE FROM HYDRAULIC CIRCUIT........................................................... 491 PROCEDURE FOR SIMPLE TEST OF STEERING BRAKE PERFORMANCE....................................................... 492 PROCEDURE FOR TESTING SENSORS................................................................................. 493 TESTING AND ADJUSTING "OPEN" AND "CLOSE" LOCK AND STEADY REST OF OPERATORS CAB DOOR........................... 495 TROUBLESHOOTING............................................................................................... 498 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................... 499 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................... 500 POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE.......................................................... 501 CHECKS BEFORE TROUBLESHOOTING............................................................................. 509 METHOD OF USING MATRIX TROUBLESHOOTING CHART.............................................................. 510 METHOD OF USING TROUBLESHOOTING CHARTS.................................................................... 514 TYPE OF CONNECTOR AND POSITION OF INSTALLATION............................................................ 516 CONNECTOR POSITION DRAWING................................................................................ 521 CONNECTION TABLE FOR CONNECTOR PIN NUMBERS................................................................ 523 ELECTRICAL CIRCUIT DIAGRAM FOR EACH SYSTEM................................................................ 546 TROUBLESHOOTING OF ENGINE (S MODE)........................................................................ 550 S-1 STARTING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME)......................................... 551 S-2 ENGING DOES NOT START............................................................................. 552 (1) ENGINE DOES NOT TURN.......................................................................... 552 (2) ENGINE TURNS BUT NO EXHAUST GAS COMES OUT (FUEL IS NOT BEING INJECTED)........................ 553 (3) EXHAUST GAS COMES OUT BUT ENGINE DOES NOT START (FUEL IS BEING INJECTED)...................... 554 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR).............................................. 555 S-4 ENGINE STOPS DURING OPERATIONS.................................................................... 556 S-5 ENGINE DOES NO ROTATE SMOOTHLY (HUNTING).......................................................... 557 S-6 ENGINE LACKS OUTPUT (NO POWER).................................................................... 558 S-7 EXHAUST GAS IS BLACK (INCOMPLETE COMBUSTION)...................................................... 559 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST GAS IS BLUE)............................................. 560 S-9 OIL BECOMES CONTAMINATED QUICKLY.................................................................. 561 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................... 562 S-11 OIL IS IN COOLING WATER, OR WATER SPURTS BACK, OR WATER LEVEL GOES DOWN.......................... 563 S-12 OIL PRESSURE LAMP LIGHTS UP (DROP IN OIL PRESSURE)............................................... 564 S-13 OIL LEVEL RISES.................................................................................. 565 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)................................................. 566 S-15 ABNORMAL NOISE IS MADE........................................................................... 567 S-16 VIBRATION IS EXCESSIVE........................................................................... 568 TROUBLESHOOTING OF HYDRAULIC,MECHANICAL SYSTEM (H MODE)................................................... 569 TABLE OF FAILURE MODES AND CAUSES (HYDRAULIC,MECHANICAL SYSTEMS)...................................... 570 H-1 BRAKE DOES NOT WORK............................................................................... 571 H-2 MACHINE DOES NOT TURN (CAN TRAVEL IN A STRAIGHT LINE) (D65E,P-12)................................. 572 H-3 TURNING SPEED IS SLOW (CANNOT TURN) OR LACKS POWER WHEN TURNING (D65EX,PX-12)..................... 574 H-4 OVERRUNS WHEN TURNING (D65E,P-12)................................................................. 576 H-5 CAN TURN IN ONLY ONE DIRECTION (WHEN STEERING LEVER IS OPERATED) (D65E,P-12)...................... 577 H-6 EXCESSIVE TIME LAG................................................................................ 579 H-7 MACHINE CAN TRAVEL IN ONLY ONE DIRECTION (FORWARD OR REVERSE)..................................... 579 H-8 MACHINE DOES NOT MOVE (WHEN ENGINE IS STARTED AND LEVER IS SHIFTED TO 2ND OR 3RD)................. 580 1) D65E,P-12...................................................................................... 580 2) D65EX,PX-12.................................................................................... 582 H-9 MACHINE DOES NOT MOVE IN ANY SPEED RANGE.......................................................... 584 1) D65E,P-12...................................................................................... 584 2) D65EX,PX-12.................................................................................... 586 H-10 POWER TRAIN OIL TEMPERATURE RISES TOO HIGH....................................................... 588 H-11 DRAWBAR PULL IS WEEK,TRAVEL SPEED IS SLOW........................................................ 590 1) D65E,P-12...................................................................................... 590 2) D65EX,PX-12.................................................................................... 592 H-13 ABNORMAL NOISES IS GENERATED FROM AROUND HYDRAULIC PUMP OR HYDRAULIC,HSS PUMP.................... 593 H-14 SPEED OF ALL WORK EQUIPMENT IS SLOW (D65E,P-12).................................................. 594 H-15 NO WORK EQUIPMENT MOVES (D65E,P-12).............................................................. 596 H-16 ALL WORK EQUIPMENT LACKS POWER (D65E,P-12)....................................................... 596 H-17 TURNING SPEED AND SPEED OF ALL WORK EQUIPMENT IS SLOW (D65EX,PX-12).............................. 597 H-18 MACHINE CANNOT TURN AND NO WORK EQUIPMENT MOVES (D65EX,PX-12).................................... 599 H-19 TURNING AND ALL WORK EQUIPMENT LACKS POWER (D65EX,PX-12)......................................... 599 H-20 BLADE LIFTING SPEED IS SLOW OR LACKS POWER....................................................... 600 1) D65E,P-12...................................................................................... 600 2) D65EX,PX-12.................................................................................... 600 H-21 BLADE TILT SPEED IS SLOW OR LACKS POWER.......................................................... 601 1) D65E,P-12...................................................................................... 601 2) D65EX,PX-12.................................................................................... 601 H-22 HYDRAULIC DRIFT OF BLADE LIFY IS EXCESSIVE....................................................... 602 H-23 HYDRAULIC DRIFT OF BLADE TILT IS EXCESSIVE....................................................... 602 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E MODE)............................................................. 603 TABLE OF FAILURE MODES AND CAUSES (ELECTRICAL SYSTEM)................................................. 604 E-1 STARTING MOTOR IS NOT CRANKED WHEN STARTING SWITCH IS TURNED TO 0N................................ 605 E-2 LAMP DO NOT LIGHT UP.............................................................................. 611 a) FRONT LAMPS.................................................................................... 611 b) REAR LAMPS..................................................................................... 612 E-4 AUTOMATIC PREHEATING IS NOT CARRIED OUT WHEN GLOW SWITCH IS TURNED TO AUTO ....................... 615 E-5 WIPER DOES NOT WORK............................................................................... 621 E-6 NO WASHER FLUID IS SPRAYED OUT.................................................................... 623 E-7 AIR CONDITION HAS NOT EFFECT...................................................................... 625 a) NO AIR COMES OUT............................................................................... 625 b) DOES NOT BECOME COOL .......................................................................... 629 TROUBLESHOOTING OF MACHINE MONITOR SYSTEM (M MODE)........................................................ 633 TABLE OF FAILURE MODES AND CAUSES (MACHINE MONITOR SYSTEM)............................................ 634 M-1 NO DISPLAY IS GIVEN ON MONITOR PANEL WHEN STARTING SWITCH IS TURNED TO ON......................... 635 M-2 WHEN STARTING SWITCH IS TURNED ON, ALL MONITOR PANEL LAMPS LIGHT UP AND DO NOT GO OUT............. 635 M-3 PREHEATING DISPLAY IS ABNORMAL.................................................................... 636 a) PREHEATING MONITOR DOES NOT LIGHT UP........................................................... 636 b) PREHEATING MONITOR DOES NOT GO OUT............................................................. 636 M-4 CAUTION ITEMS LIGHT UP OR FLASH................................................................... 642 a) (CHARGE) LIGHTS UP OR FLASHES.................................................................. 642 b) WHEN STARTING SWITCH AT ON AND ENGINE IS STARTED (ENGINE OIL PRESSURE) LIGHTS UP OR FLASHES.... 643 c) (COOLANT TEMPERATURE) FLASHES.................................................................. 644 d) (POWER TRAIN OIL TEMPERATURE) FLASHES.......................................................... 646 M-5 BUZZER IS ABNORMAL................................................................................ 648 a) CAUTION ITEMS FLASHES BUT BUZZER DOES NOT SOUND................................................ 648 b) MONITOR DISPLAY IS NORMAL, BUT BUZZER SOUNDS................................................... 648 M-6 WARNING LAMP IS ABNORMAL.......................................................................... 649 a) CAUTION ITEM FLASHING BUT LAMP DOES NOT FLASH.................................................. 649 b) MONITOR DISPLAY IS NORMAL BUT LAMP FLASHES..................................................... 649 M-7 GAUGE IS ABNORMAL................................................................................. 650 a) ABNORMALITY IN ENGINE COOLANT TEMPERATURE GAUGE................................................ 650 b) ABNORMALITY IN POWER TRAIN OIL TEMPERATURE GAUGE............................................... 651 c) ABNORMALITY IN FUEL LEVEL GAUGE................................................................ 652 M-8 SERVICE METER DOES NOT MOVE AFTER ENGINE IS STARTED............................................... 656 M-9 MONITOR PANEL LIGHTING DOES NOT LIGHT UP (FRONT LAMPS ARE NORMAL)................................. 657 30 DISASSEMBLY AND ASSEMBLY....................................................................................... 659 METHOD OF USING MANUAL........................................................................................ 662 PRECAUTIONS WHEN CARRYING OUT OPERATION....................................................................... 663 SPECIAL TOOL LIST............................................................................................. 665 SPECIAL TOOL SKETCH........................................................................................... 670 STARTING MOTOR................................................................................................ 671 REMOVAL................................................................................................... 671 INSTALLATION.............................................................................................. 671 ALTERNATOR ASSEMBLY........................................................................................... 672 REMOVAL................................................................................................... 672 INSTALLATION.............................................................................................. 672 ENGINE OIL COOLER CORE........................................................................................ 674 REMOVAL................................................................................................... 674 INSTALLATION.............................................................................................. 674 FUEL INJECTION PUMP ASSEMBLY.................................................................................. 675 REMOVAL................................................................................................... 675 INSTALLATION.............................................................................................. 676 WATER PUMP ASSEMBLY........................................................................................... 677 REMOVAL................................................................................................... 677 INSTALLATION.............................................................................................. 677 TURBOCHARGER ASSEMBLY......................................................................................... 679 REMOVAL................................................................................................... 679 INSTALLATION.............................................................................................. 679 NOZZLE HOLDER ASSEMBLY (D65P,EX,PX)........................................................................... 680 REMOVAL................................................................................................... 680 INSTALLATION.............................................................................................. 680 NOZZLE HOLDER ASSEMBLY (D65E)................................................................................. 681 REMOVAL................................................................................................... 681 INSTALLATION.............................................................................................. 681 THERMOSTAT ASSEMBLY........................................................................................... 682 REMOVAL................................................................................................... 682 INSTALLATION.............................................................................................. 682 CYLINDER HEAD ASSEMBLY (D65P,EX,PX)........................................................................... 684 REMOVAL................................................................................................... 684 INSTALLATION.............................................................................................. 688 CYLINDER HEAD ASSEMBLY (D65E)................................................................................. 696 REMOVAL................................................................................................... 696 INSTALLATION.............................................................................................. 699 ENGINE FRONT SEAL............................................................................................. 706 REMOVAL................................................................................................... 706 INSTALLATION.............................................................................................. 707 ENGINE REAR SEAL.............................................................................................. 708 REMOVAL................................................................................................... 708 INSTALLATION.............................................................................................. 709 AIR CONDITIONER COMPRESSOR ASSEMBLY........................................................................... 712 REMOVAL................................................................................................... 712 INSTALLATION.............................................................................................. 712 AIR CONDITIONER CONDENSER ASSEMBLY............................................................................ 713 REMOVAL................................................................................................... 713 INSTALLATION.............................................................................................. 713 FUEL TANK ASSEMBLY............................................................................................ 714 REMOVAL................................................................................................... 714 INSTALLATION.............................................................................................. 715 RADIATOR ASSEMBLY............................................................................................. 720 REMOVAL................................................................................................... 720 INSTALLATION.............................................................................................. 722 ENGINE ASSEMBLY (CAB SPECIFICATION)........................................................................... 723 REMOVAL................................................................................................... 723 INSTALLATION.............................................................................................. 726 ENGINE ASSEMBLY (CANOPY SPECIFICATION)........................................................................ 731 REMOVAL................................................................................................... 731 INSTALLATION.............................................................................................. 733 DAMPER ASSEMBLY............................................................................................... 737 REMOVAL................................................................................................... 737 INSTALLATION.............................................................................................. 739 POWER TRAIN UNIT ASSEMBLY (D65E,P)............................................................................ 741 REMOVAL................................................................................................... 741 INSTALLATION.............................................................................................. 746 POWER TRAIN UNIT ASSEMBLY (D65EX,PX).......................................................................... 747 REMOVAL................................................................................................... 747 INSTALLATION.............................................................................................. 752 POWER TRAIN UNIT (D65E,P)..................................................................................... 753 SEPARATION................................................................................................ 753 CONNECTION................................................................................................ 756 POWER TRAIN UNIT (D65EX,PX)................................................................................... 757 SEPARATION................................................................................................ 757 CONNECTION................................................................................................ 760 TORQUE CONVERTER ASSEMBLY..................................................................................... 761 DISASSEMBLY............................................................................................... 761 ASSEMBLY.................................................................................................. 763 PTO ASSEMBLY.................................................................................................. 766 DISASSEMBLY............................................................................................... 766 ASSEMBLY.................................................................................................. 769 TORQFLOW TRANSMISSION ASSEMBLY................................................................................ 773 DISASSEMBLY............................................................................................... 773 ASSEMBLY.................................................................................................. 792 STEERING CASE ASSEMBLY (D65E,P)............................................................................... 820 DISASSEMBLY............................................................................................... 820 ASSEMBLY.................................................................................................. 833 HSS ASSEMBLY (D65EX,PX)....................................................................................... 855 DISASSEMBLY............................................................................................... 855 ASSEMBLY.................................................................................................. 876 TORQUE CONVERTER VALVE ASSEMBLY............................................................................... 900 REMOVAL................................................................................................... 900 INSTALLATION.............................................................................................. 900 DISASSEMBLY............................................................................................... 901 ASSEMBLY.................................................................................................. 901 TRANSMISSION CONTROL VALVE ASSEMBLY........................................................................... 902 REMOVAL................................................................................................... 902 INSTALLATION.............................................................................................. 902 DISASSEMBLY............................................................................................... 904 ASSEMBLY.................................................................................................. 904 STEERING CONTROL VALVE ASSEMBLY (D65E,P)...................................................................... 908 REMOVAL................................................................................................... 908 INSTALLATION.............................................................................................. 908 DISASSEMBLY............................................................................................... 909 ASSEMBLY.................................................................................................. 911 BRAKE VALVE ASSEMBLY (D65EX,PX)............................................................................... 913 REMOVAL................................................................................................... 913 INSTALLATION.............................................................................................. 913 DISASSEMBLY............................................................................................... 914 ASSEMBLY.................................................................................................. 915 REDUCING VALVE ASSEMBLY (D65E,P).............................................................................. 916 REMOVAL................................................................................................... 916 INSTALLATION.............................................................................................. 916 DISASSEMBLY............................................................................................... 917 ASSEMBLY.................................................................................................. 917 HSS MOTOR ASSEMBLY (D65EX,PX)................................................................................. 918 REMOVAL................................................................................................... 918 INSTALLATION.............................................................................................. 918 DISASSEMBLY............................................................................................... 919 ASSEMBLY.................................................................................................. 923 SCAVENGING PUMP ASSEMBLY...................................................................................... 930 REMOVAL................................................................................................... 930 INSTALLATION.............................................................................................. 930 POWER TRAIN PUMP ASSEMBLY..................................................................................... 931 REMOVAL................................................................................................... 931 INSTALLATION.............................................................................................. 931 FINAL DRIVE ASSEMBLY.......................................................................................... 932 REMOVAL................................................................................................... 932 INSTALLATION.............................................................................................. 933 DISASSEMBLY............................................................................................... 934 ASSEMBLY.................................................................................................. 938 TRACK FRAME ASSEMBLY.......................................................................................... 943 REMOVAL................................................................................................... 943 INSTALLATION.............................................................................................. 944 RECOIL SPRING ASSENBLY........................................................................................ 945 REMOVAL................................................................................................... 945 INSTALLATION.............................................................................................. 945 DISASSEMBLY............................................................................................... 947 ASSEMBLY.................................................................................................. 949 IDLER ASSEMBLY................................................................................................ 953 REMOVAL................................................................................................... 953 INSTALLATION.............................................................................................. 953 DISASSEMBLY............................................................................................... 955 ASSEMBLY.................................................................................................. 956 TRACK ROLLER ASSEMBLY......................................................................................... 961 REMOVAL................................................................................................... 961 INSTALLATION.............................................................................................. 961 DISASSEMBLY............................................................................................... 962 ASSEMBLY.................................................................................................. 963 CARRIER ROLLER ASSEMBLY (D65P,PX)............................................................................. 965 REMOVAL................................................................................................... 965 INSTALLATION.............................................................................................. 965 CARRIER ROLLER ASSEMBLY (D65E,EX)............................................................................. 966 REMOVAL................................................................................................... 966 INSTALLATION.............................................................................................. 966 DISASSEMBLY (D65E,P,EX,PX)................................................................................ 967 ASSEMBLY (D65E,P,EX,PX)................................................................................... 968 TRACK SHOE.................................................................................................... 969 CHECKING BEFORE REMOVAL................................................................................... 969 REMOVAL (NORMAL).......................................................................................... 969 REMOVAL (WHEN THERE IS ABNORMALITY INSIDE TRACK FRAME).................................................... 970 INSTALLATION.............................................................................................. 971 OVERALL DISASSEMBLY....................................................................................... 975 OVERALL ASSEMBLY.......................................................................................... 980 PRESS-FITTING JIG DIMENSION TABLE FOR LINK PRESS.......................................................... 994 FIELD DISASSEMBLY OF ONE LINK............................................................................. 995 FIELD ASSEMBLY OF ONE LINK................................................................................ 996 PIVOT SHAFT ASSEMBLY..........................................................................................1002 REMOVAL...................................................................................................1002 INSTALLATION..............................................................................................1002 EQUALIZER BAR ASSEMBLY........................................................................................1003 REMOVAL...................................................................................................1003 INSTALLATION..............................................................................................1004 EQUALIZER SIDE BUSHING........................................................................................1005 REMOVAL...................................................................................................1005 INSTALLATION..............................................................................................1005 SEGMENT TEETH.................................................................................................1006 REMOVAL...................................................................................................1006 INSTALLATION..............................................................................................1006 WORK EQUIPMENT PUMP ASSEMBLY (D65E,P).........................................................................1007 REMOVAL...................................................................................................1007 INSTALLATION..............................................................................................1007 HSS, WORK EQUIPMENT PUMP ASSEMBLY (D65EX,PX)..................................................................1008 REMOVAL...................................................................................................1008 INSTALLATION..............................................................................................1008 DISASSEMBLY...............................................................................................1009 ASSEMBLY..................................................................................................1014 PPC PUMP ASSEMBLY.............................................................................................1023 REMOVAL...................................................................................................1023 INSTALLATION..............................................................................................1023 MAIN CONTROL VALVE ASSEMBLY...................................................................................1024 REMOVAL...................................................................................................1024 INSTALLATION..............................................................................................1024 DISASSEMBLY (3-SPOOL VALVE)...............................................................................1027 ASSEMBLY..................................................................................................1029 MAIN RELIEF VALVE.............................................................................................1035 REMOVAL...................................................................................................1035 INSTALLATION..............................................................................................1035 PPC VALVE ASSEMBLY............................................................................................1036 REMOVAL (FOR WORK EQUIPMENT)..............................................................................1036 INSTALLATION (FOR WORK EQUIPMENT).........................................................................1036 REMOVAL (D65EX,PX,FOR STEERING)...........................................................................1038 INSTALLATION (D65EX,PX,FOR STEERING)......................................................................1039 DISASSEMBLY (FOR WORK EQUIPMENT)..........................................................................1042 ASSEMBLY (FOR WORK EQUIPMENT).............................................................................1043 DISASSEMBLY (D65EX,PX,FOR STEERING) ......................................................................1044 ASSEMBLY (D65EX,PX,FOR STEERING)..........................................................................1045 PPC CHARGE RELIEF VALVE ASSEMBLY..............................................................................1046 REMOVAL...................................................................................................1046 INSTALLATION..............................................................................................1046 DISASSEMBLY...............................................................................................1047 ASSEMBLY..................................................................................................1047 SUCTION VALVE ASSEMBLY........................................................................................1048 REMOVAL...................................................................................................1048 INSTALLATION..............................................................................................1048 BLADE LIFT CYLINDER ASSEMBLY..................................................................................1049 REMOVAL...................................................................................................1049 INSTALLATION..............................................................................................1049 BLADE TILT CYLINDER ASSEMBLY..................................................................................1050 REMOVAL...................................................................................................1050 INSTALLATION..............................................................................................1050 HYDRAULIC CYLINDER ASSEMBLY (BLADE LIFT, BLADE TILT CYLINDER).................................................1051 DISASSEMBLY...............................................................................................1051 ASSEMBLY..................................................................................................1053 WORK EQUIPMENT ASSEMBLY.......................................................................................1056 REMOVAL...................................................................................................1056 INSTALLATION..............................................................................................1057 DISASSEMBLY...............................................................................................1058 ASSEMBLY..................................................................................................1060 RIPPER VALVE ASSEMBLY (OPT.)..................................................................................1062 DISASSEMBLY...............................................................................................1062 ASSEMBLY..................................................................................................1063 ROPS GUARD....................................................................................................1064 REMOVAL...................................................................................................1064 INSTALLATION..............................................................................................1064 OPERATOR'S CAB ASSEMBLY.......................................................................................1065 REMOVAL...................................................................................................1065 INSTALLATION..............................................................................................1066 CANOPY ASSEMBLY...............................................................................................1067 REMOVAL...................................................................................................1067 INSTALLATION..............................................................................................1067 DASHBOARD ASSEMBLY............................................................................................1068 REMOVAL...................................................................................................1068 INSTALLATION..............................................................................................1068 MONITOR ASSEMBLY..............................................................................................1069 REMOVAL...................................................................................................1069 INSTALLATION..............................................................................................1069 FLOOR FRAME ASSEMBLY (D65E,P).................................................................................1070 REMOVAL...................................................................................................1070 INSTALLATION..............................................................................................1073 FLOOR FRAME ASSEMBLY (D65EX,PX)...............................................................................1078 REMOVAL...................................................................................................1078 INSTALLATION..............................................................................................1081 40 MAINTENANCE STANDARD...........................................................................................1086 ENGINE MOUNT..................................................................................................1087 POWER TRAIN UNIT MOUNT........................................................................................1088 DAMPER, UNIVERSAL JOINT.......................................................................................1089 TORQUE CONVERTER, PTO.........................................................................................1090 TRANSMISSION..................................................................................................1092 TRANSMISSION CONTROL VALVE....................................................................................1096 MAIN RELIEF VALVE.............................................................................................1099 BEVEL GEAR SHAFT, STEERING CLUTCH, STEERING BRAKE (D65E,P-12).................................................1100 BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)......................................................1104 BEVEL GEAR SHAFT, HSS STEERING BRAKE (2/2) (D65EX,PX-12)......................................................1106 BEVEL GEAR SHAFT, HSS STEERING BRAKE (1/2) (D65EX,PX-12)......................................................1108 STEERING CONTROL VALVE (D65E,P-12)............................................................................1111 BEVEL GEAR SHAFT, HSS BRAKE VALVE (D65EX,PX-12)...............................................................1112 POWER TRAIN, LUBRICATION PUMP.................................................................................1113 PPC PUMP......................................................................................................1114 PPC VALVE.....................................................................................................1116 FOR STEERING (D65EX,PX-12)................................................................................1116 FOR BLADE LIFT, BLADE TILT, RIPPER LIFT (D65E,P-12,D65EX,PX-12)...........................................1117 PPC CHARGE VALVE..............................................................................................1121 FINAL DRIVE...................................................................................................1122 HULL FRAME....................................................................................................1124 TRACK FRAME, RECOIL SPRING....................................................................................1125 IDLER.........................................................................................................1127 TRACK ROLLER..................................................................................................1130 CARRIER ROLLER................................................................................................1132 SPROCKET TOOTH PROFILE........................................................................................1133 TRACK SHOE (DRY TYPE).........................................................................................1134 TRACK SHOE (LUBRICATION TYPE).................................................................................1136 SUSPENSION....................................................................................................1138 HYDRAULIC PUMP (D65E,P-12)....................................................................................1142 HYDRAULIC, HSS PUMP (D65EX,PX-12).............................................................................1144 HSS MOTOR (D65EX,PX-12).......................................................................................1145 MAIN CONTROL VALVE............................................................................................1146 2+1-SPOOL VALVE (D65E,P-12)...............................................................................1146 3+1-SPOOL VALVE (D65EX,PX-12).............................................................................1156 WORK EQUIPMENT CYLINDER.......................................................................................1166 WORK EQUIPMENT................................................................................................1168 CUTTING EDGE, END BIT.........................................................................................1174 RIPPER........................................................................................................1175 90 OTHERS.........................................................................................................1176 SPECIFICATIONS................................................................................................1177 SPECIFICATION DRAWING.....................................................................................1177 SPECIFICATIONS............................................................................................1178 WEIGHT TABLE..............................................................................................1184 TABLE OF FUEL, COOLANT AND LUBRICANTS.....................................................................1187 STRUCTURE AND FUNCTION........................................................................................1188 REAR GUARD................................................................................................1188 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM...................................................................1189 STEERING AND WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM.....................................................1190 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM..................................................................1192 WORK EQUIPMENT CONTROL....................................................................................1193 MAIN CONTROL VALVE........................................................................................1194 TRIMMING DOZER............................................................................................1198 MAINTENANCE STANDARD..........................................................................................1199 MAIN CONTROL VALVE........................................................................................1199 WORK EQUIPMENT CYLINDER...................................................................................1208 TRIMMING DOZER............................................................................................1210 D65EX,PX-12 (FOR KA SPEC.)....................................................................................1211 STRUCTURE AND FUNCTION........................................................................................1212 ENGINE CONTROL............................................................................................1212 TRANSMISSION CONTROL......................................................................................1213 STEERING AND BRAKE CONTROL................................................................................1214 PPC CONTROL PIPING DIAGRAM................................................................................1215 TESTING AND ADJUSTING.........................................................................................1216 STANDARD VALUE TABLE FOR CHASSIS..........................................................................1216 ADJUSTING FUEL CONTROL LINKAGE............................................................................1218 ADJUSTING LINKAGE OF FORWARD-REVERSE LEVER, GEAR SHIFT LEVER, AND PARKING BRAKE LEVER.....................1220 TROUBLESHOOTING...............................................................................................1222 CONNECTOR TYPES AND MOUNTING LOCATIONS....................................................................1222 CONNECTOR POSITION DRAWING................................................................................1223 ELECTRIC CIRCUIT DIAGRAM......................................................................................1225 ELECTRIC CIRCUIT DIAGRAM FOR CAB..........................................................................1225 CAB SPECIFICATION.........................................................................................1226 CANOPY SPECIFICATION......................................................................................1227
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