Komatsu Bulldozer D68ESS-12 service & repair manual

Description Komatsu Bulldozer D68ESS-12 service & repair manual

Komatsu Bulldozer D68ESS-12 pdf workshop service repair manual

Serial numbers:
1001 and up
J10001 and up

Technical data, specifications, maintenance, testing, 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
Damper, universal joint
Torque converter and PTO
Transmission control
Transmission
Transmission control valve
Main relief valve
Lubrication relief valve
Steering and brake control
Bevel gear shaft, steering clutch and brake
Brake valve
Scavenging pump strainer
Power train oil strainer
Power train oil filter
Final drive
Undercarriage and frame
Main frame
Suspension
Track frame
Recoil spring
Idler
Track roller
Carrier roller
Track shoe
Hydraulic system
Work equipment hydraulic piping diagram
PPC control piping diagram
Work equipment control
Hydraulic tank and filter
Hydraulic pump
Power train lubrication pump
PPC valve (for steering)
PPC charge valve
1-spool valve
Main control valve
CLSS
Functions, operation of valve
Suction valve
3-spool valve
Main control valve
CLSS
Functions, operation of valve
Suction valve
Work equipment
Cutting edge, end bit
Work equipment cylinder
Electrical system
Engine control
Machine monitor system
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
Measuring blow-by pressure
Measuring exhaust color
Measuring engine oil pressure
Measuring engine speed
Testing fan belt tension
Measuring speed at torque converter stall
Adjusting fuel control linkage
Adjusting steering/directional lever, gearshift lever, and parking brake lever
Adjusting brake pedal linkage
Adjusting work equipment lock lever
Measuring power train hydraulic pressure
Measuring and adjusting work equipment oil pressure
Measuring leakage inside cylinder
Bleeding air from hydraulic cylinder

Troubleshooting
General information on troubleshooting
Points to remember when troubleshooting
How to proceed troubleshooting
Connector types and mounting locations
Connector pin arrangement diagram
How to distinguish wire code
Wiring table for connector pin numbers
T-adapter box and T-adapter table
How to follow the troubleshooting flow diagrams
Troubleshooting of electrical system (E-mode)
Table of failure modes and causes (Electrical system)
Electrical circuit diagram for each system
E-1 Starting motor is not cranked when starting switch is turned to ON
E-2 Lamps do not light up
Troubleshooting of hydraulic and mechanical system (H-mode)
Table of failure modes and causes (hydraulic, mechanical system)
H-1 Brake does not work
H-2 Machine does not turn (can travel in a straight line)
H-3 Overruns when turning
H-4 Can turn in only one direction (when steering lever is operated)
H-5 Excessive time lag
H-6 Machine can travel in only one direction (forward or reverse)
H-7 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd)
H-8 Machine does not move in any speed range
H-9 Power train oil temperature rises too high
H-10 Drawbar pull is weak, travel speed is slow
H-11 Abnormal noise is generated from around hydraulic pump
H-12 Work equipment speed is slow or lacks power
H-13 No work equipment moves
H-14 Blade lift or tilt cylinder speed is slow or lacks power
H-15 Blade angle cylinder speed is slow or lacks power
H-16 Hydraulic drift of blade lift is excessive
H-17 Hydraulic drift of blade tilt is excessive
H-18 Hydraulic drift of blade angle is excessive

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 engine assembly
Removal and installation of radiator and guard assembly
Removal and installation of radiator assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of fuel tank assembly
Removal and installation of damper assembly
Power train
Removal and installation of PTO, torque converter and transmission assembly
Disconnection 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 steering clutch and brake assembly
Disassembly and assembly of steering clutch and brake assembly
Removal and installation of bevel gear and bevel gear shaft (Clutch and brake model)
Removal and installation of brake valve assembly
Disassembly and assembly of brake valve assembly
Removal and installation of scavenging pump assembly
Removal and installation of power train and lubricating oil pump assembly
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 recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of idler assembly
Disassembly and assembly of idler 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
Removal and installation of track shoe assembly
Overall disassembly and assembly of track shoe assembly
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 installation of segment teeth
Hydraulic system
Removal and installation of work equipment pump assembly
Removal and installation of work equipment control valve assembly
Disassembly and assembly of work equipment control valve assembly
Removal and installation of steering PPC valve assembly
Disassembly and assembly of steering PPC valve assembly
Removal and installation of suction valve assembly
Removal and installation of blade angle cylinder assembly
Removal and installation of blade tilt cylinder assembly
Removal and installation of blade lift cylinder assembly
Disassembly and assembly of hydraulic cylinder assembly
Work equipment
Removal and installation of work equipment assembly
Disassembly and assembly of work equipment assembly
Cab and its attachments
Removal and installation of floor frame assembly
Removal and installation of sweep guard
Electrical system
Removal and installation of dashboard assembly
Removal and installation of panel assembly

Diagrams and drawings
Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Work equipment hydraulic circuit diagram (1-spool valve (angle dozer))
Work equipment hydraulic circuit diagram (3-spool valve (angle tilt dozer))
Work equipment hydraulic circuit diagram (2-spool valve (trimming dozer))
Electrical diagrams and drawings
Forestry specification, general construction specification
Electrical circuit diagram (Serial No. 1001 – 1002, J10001 – J10010)
Electrical circuit diagram (Serial No. 1003 and up, J10011 and up)
Trimming dozer
Electrical circuit diagram

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