Komatsu Bulldozer D63E-12 service & repair manual

Description Komatsu Bulldozer D63E-12 service & repair manual

Komatsu Bulldozer D63E-12 pdf workshop service manual

Serial numbers:
2001 and up

Specifications, maintenance, testing, technical documentation, troubleshooting, electrical wiring diagrams, hydraulic schematics, adjusting, assembly, disassembly, removal, installation instructions and other information

MANUAL CONTENT:
Index and foreword
Composition of shop manual
Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table

Specification
Specification and technical data
Specification drawing
Weight table
Table of fuel, coolant and lubricants

Structure, function and maintenance standard
Engine and cooling system
Radiator, power train, oil cooler
Engine control
Power train
Power train system
Power train skeleton
Power train unit
Power train hydraulic piping diagram
Transmission, steering and brake control
Damper, universal joint
Torque converter and PTO
Transmission
Transmission control valve
Main relief valve
Lubrication relief valve
Power train oil filter
Final drive
Bevel gear shaft, steering clutch and brake
Brake valve
Reducing valve
Scavenging pump strainer
Power train pump strainer
Undercarriage and frame
Main frame
Suspension
Track frame
Recoil spring
Idler
Track roller
Carrier roller
Track shoe
Hydraulic system
Work equipment hydraulic piping diagram
Work equipment control
Hydraulic tank and filter
Hydraulic pump
Power train lubrication pump
Control valve
CLSS
Functions and operation by valve
PPC valve
Suction valve
Work equipment
Cutting edge, end bit
Ripper
Work equipment cylinder
Cab and its attachments
Cab mount
Cab
ROPS guard
Electrical system
Machine monitor system
Monitor panel
Engine control
Sensors

Standard value table
Standard service value table
Standard value table for engine
Standard value table for chassis
Standard value table for electrical system

Testing and adjusting
Tools for testing, adjusting, and troubleshooting
Testing engine speed
Testing blow-by pressure
Testing exhaust color
Testing air boost pressure
Testing and adjusting valve clearance
Testing compression pressure
Testing and adjusting fuel injection timing
Testing exhaust temperature
Testing engine oil pressure
Testing and adjusting engine stop solenoid
Testing and adjusting fan belt tension
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Testing speed at torque converter stall
Adjusting fuel control linkage
Adjusting linkages of steering, forward-reverse lever, gear shift lever, and parking brake lever
Adjusting brake pedal linkage
Adjusting work equipment lock lever
Adjusting straight tiltdozer and U-dozer
Testing power train hydraulic pressure
Testing and adjusting work equipment oil pressure
Testing leakage inside cylinder
Bleeding air from hydraulic cylinder
Procedure for simple test of steering brake performance

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
Sequence of events in troubleshooting
Testing before troubleshooting
How to follow the troubleshooting flow diagrams
Connection table for connector pin numbers
T- branch box and T- branch adapter table
Troubleshooting of electrical system (E-mode)
Troubleshooting of hydraulic and mechanical system (H-mode)
Troubleshooting of engine (S-mode)
Troubleshooting of machine monitor system (M-mode)

Disassembly and assembly
General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
Engine and cooling system
Removal and installation of radiator and radiator guard assembly
Removal and installation of engine assembly
Removal and installation of coolant heater assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of damper assembly
Removal and installation of fuel tank assembly
Removal and installation of engine hood assembly
Removal and installation of fuel injection pump assembly
Removal and installation of fuel injection nozzle assembly
Removal and installation of cylinder head assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Power train
Removal and installation of PTO, torque converter and transmission assembly
Separation and connection of PTO, torque converter and transmission assembly
Disassembly and assembly of PTO assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of TORQFLOW transmission assembly
Removal and installation of torque converter main relief valve assembly
Disassembly and assembly of torque converter main relief valve assembly
Removal and installation of transmission control valve assembly
Disassembly and assembly of transmission control valve assembly
Removal and installation of brake valve assembly
Disassembly and assembly of brake valve assembly
Removal and installation of steering clutch and brake assembly
Disassembly and assembly of steering clutch and brake assembly
Removal and installation of bevel gear and bevel gear shaft
Removal and installation of final drive assembly
Disassembly and assembly of final drive assembly
Undercarriage and frame
Removal and installation of track frame assembly
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Check before expanding track shoe assembly
Expansion (normal), expansion (internal abnormality) and installation of track shoe assembly
Overall disassembly and overall assembly of track shoe assembly
Link press-fitting jig dimensions table
Field disassembly and assembly of one link
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Removal and installation of equalizer bar side bushing
Removal and installation of segment teeth
Hydraulic system
Removal and installation of work equipment valve assembly
Disassembly and assembly of work equipment control valve assembly
Removal and installation of scavenging pump
Removal and installation of power train and lubricating oil pump assembly
Removal and installation of work equipment pump assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of blade assembly
Removal and installation of ripper assembly
Cab and its attachments
Removal and installation of ROPS guard assembly
Removal and installation of operator cab assembly
Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of floor frame assembly
Removal and installation of heater unit assembly
Removal and installation of monitor panel assembly
Removal and installation of dashboard assembly

Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Steering, work equipment hydraulic circuit diagram
Electrical diagrams and drawings
Electrical circuit diagram
Electrical circuit diagram (Inside cab)
Connector list and stereogram

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