Complete service repair manual with Electrical Wiring Diagrams for Komatsu BULLDOZERS D68ESS, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.
Komatsu BULLDOZERS D68ESS workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.
PRODUCT DETAILS:
Total Pages: 812 pages
File Format: PDF
Language: English
SEN01128-06 – BULLDOZER D68ESS-12 Shop Manual.pdf
PEN00166-00 – BULLDOZER D68ESS-12 Operation & Maintenance Manual.pdf
MAIN SECTIONS
Cover….1
00 Index and foreword….3
Index….3
Composition of shop manual….4
Table of contents….6
Foreword and general information….13
Safety notice….14
How to read the shop manual….19
Explanation of terms for maintenance standard….21
Handling of connectors newly used for engines….32
How to read electric wire code….35
Precautions when carrying out operation….38
Method of disassembling and connecting push-pull type coupler….41
Standard tightening torque table….44
Conversion table….48
01 Specification….55
Specification and technical data….55
Specification and technical data….56
Specification drawing….56
Specifications….58
Weight table….62
Table of fuel, coolant and lubricants….64
10 Structure, function andmaintenance standard….67
Engine and cooling system….67
Engine and cooling system….68
Radiator, power train, oil cooler….68
Engine control….70
Power train, Part 1….73
Power train, Part 1….74
Power train system….74
Power train skeleton….75
Power train unit….76
Power train hydraulic piping diagram….77
Damper, universal joint….78
Torque converter and PTO….81
Transmission control….86
Transmission….87
Transmission control valve….96
Main relief valve….102
Lubrication relief valve….105
Steering and brake control….106
Power train, Part 2….109
Power train, Part 2….110
Bevel gear shaft, steering clutch and brake….110
Brake valve….120
Scavenging pump strainer….125
Power train oil strainer….126
Power train oil filter….127
Final drive….128
Undercarriage and frame….135
Undercarriage and frame….136
Main frame….136
Suspension….138
Track frame….141
Recoil spring….142
Idler….144
Track roller….145
Carrier roller….146
Track shoe….148
Hydraulic system, Part 1….151
Hydraulic system, Part 1….152
Work equipment hydraulic piping diagram….152
PPC control piping diagram….156
Work equipment control….157
Hydraulic tank and filter….160
Hydraulic pump….162
Power train lubrication pump….163
PPC valve (for steering)….164
PPC charge valve….169
Hydraulic system, Part 2….173
Hydraulic system, Part 2….174
1-spool valve 1….174
CLSS….180
Functions, operation of valve….182
Suction valve….190
3-spool valve 1….192
CLSS….199
Functions, operation of valve….201
Suction valve….210
Work equipment….213
Work equipment….214
Work equipment….214
Cutting edge, end bit….224
Work equipment cylinder….226
Electrical system….229
Electrical system….230
Engine control….230
Machine monitor system….231
Sensors….234
20 Standard value table….239
Standard service value table….239
Standard service value table….240
Standard value table for engine….240
Standard value table for chassis….241
Standard value table for electrical system….246
30 Testing and adjusting….249
Testing and adjusting….249
Testing and adjusting….250
Tools for testing, adjusting, and troubleshooting….250
Measuring blow-by pressure….251
Measuring exhaust color….252
Measuring engine oil pressure….253
Measuring engine speed….254
Testing fan belt tension….255
Measuring speed at torque….256
Adjusting fuel control linkage….257
Adjusting steering/directional lever, gearshift lever, and parking brake lever….259
Adjusting brake pedal linkage….262
Adjusting work equipment lock lever….263
Measuring power train hydraulic pressure….264
Measuring and adjusting work equipment oil pressure….267
Measuring leakage inside cylinder….268
Bleeding air from hydraulic cylinder….268
40 Troubleshooting….271
General information on troubleshooting….271
General information on troubleshooting….272
Points to remember when troubleshooting….272
How to proceed troubleshooting….273
Connector types and mounting locations….275
Connector pin arrangement diagram….276
How to distinguish wire code….278
Wiring table for connector pin numbers….282
T-adapter box and T-adapter table….315
How to follow the troubleshooting flow diagrams….318
Troubleshooting of electrical system (E-mode)….321
Troubleshooting of electrical system (E-mode)….322
Table of failure modes and causes (Electrical system)….322
Electrical circuit diagram for each system….324
E-1 Starting motor is not cranked when starting switch is turned to ON….332
E-2 Lamps do not light up….338
Troubleshooting of hydraulic and mechanical system (H-mode)….343
Troubleshooting of hydraulic and mechanical system (H-mode)….346
Table of failure modes and causes (hydraulic, mechanical system)….346
H-1 Brake does not work….348
H-2 Machine does not turn (can travel in a straight line)….349
H-3 Overruns when turning….350
H-4 Can turn in only one direction (when steering lever is operated)….350
H-5 Excessive time lag….351
H-6 Machine can travel in only one direction (forward or reverse)….351
H-7 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd)….352
H-8 Machine does not move in any speed range….354
H-9 Power train oil temperature rises too high….356
H-10 Drawbar pull is weak, travel speed is slow….358
H-11 Abnormal noise is generated from around hydraulic pump….360
H-12 Work equipment speed is slow or lacks power….360
H-13 No work equipment moves….361
H-14 Blade lift or tilt cylinder speed is slow or lacks power….361
H-15 Blade angle cylinder speed is slow or lacks power….362
H-16 Hydraulic drift of blade lift is excessive….362
H-17 Hydraulic drift of blade tilt is excessive….363
H-18 Hydraulic drift of blade angle is excessive….363
Troubleshooting of machine monitor system (M-mode)….365
Troubleshooting of machine monitor system (M-mode)….366
Table of failure modes and causes (machine monitor system)….366
Electrical circuit diagrams for each system….368
M-1 Caution item lights up….376
M-2 Gauge is abnormal….380
M-3 Service meter does not move after engine is started….388
M-4 Monitor panel lighting does not light up (front lamps are normal)….389
50 Disassembly and assembly….393
General information on disassembly and assembly….393
General information on disassembly and assembly….394
How to read this manual….394
Coating materials list….396
Special tool list….399
Sketches of special tools….403
Engine and cooling system….407
Engine and cooling system….408
Removal and installation of engine assembly….408
Removal and installation of….410
Removal and installation of….412
Removal and installation of….415
Removal and installation of fuel tank assembly….416
Removal and installation of….417
Power train….421
Power train….423
Removal and installation of PTO, torque converter and transmission assembly….423
Disconnection and connection of PTO, torque converter and transmission assembly….427
Disassembly and assembly of….429
Disassembly and assembly of….434
Disassembly and assembly of….438
Removal and installation of ….455
Disassembly and assembly of ….456
Removal and installation of transmission control valve assembly….457
Disassembly and assembly of transmission control valve assembly….458
Removal and installation of steering clutch and brake assembly….460
Disassembly and assembly of steering clutch and brake assembly….461
Removal and installation of bevel gear and bevel gear shaft (Clutch and brake model)….468
Removal and installation of brake valve assembly….474
Disassembly and assembly of brake valve assembly….475
Removal and installation of scavenging pump assembly….478
Removal and installation of power train and lubricating oil pump assembly….479
Removal and installation of final drive assembly….481
Disassembly and assembly of final drive assembly….482
Undercarriage and frame….495
Undercarriage and frame….496
Removal and installation of track frame assembly….496
Removal and installation of recoil spring assembly….498
Disassembly and assembly of recoil spring assembly….499
Removal and installation of idler assembly….502
Disassembly and assembly of idler assembly….503
Removal and installation of track roller assembly….507
Disassembly and assembly of track roller assembly….508
Removal and installation of carrier roller assembly….511
Disassembly and assembly of carrier roller assembly….512
Removal and installation of track shoe assembly….514
Overall disassembly and assembly of track shoe assembly….515
Field disassembly and assembly of one link….531
Removal and installation of pivot shaft assembly….538
Removal and installation of equalizer bar assembly….540
Removal and installation of equalizer bar side bushing….542
Removal installation of segment teeth….543
Hydraulic system….545
Hydraulic system….546
Removal and installation of work equipment pump assembly….546
Removal and installation of work equipment control valve assembly….547
Disassembly and assembly of work equipment control valve assembly….549
Removal and installation of steering PPC valve assembly….553
Disassembly and assembly of steering PPC valve assembly….554
Removal and installation of suction valve assembly….557
Removal and installation of blade angle cylinder assembly….558
Removal and installation of blade tilt cylinder assembly….559
Removal and installation of blade lift cylinder assembly….560
Disassembly and assembly of hydraulic cylinder assembly….561
Work equipment….567
Work equipment….568
Removal and installation of work equipment assembly….568
Disassembly and assembly of work equipment assembly….574
Cab and its attachments….579
Cab and its attachments….580
Removal and installation of floor frame assembly….580
Removal and installation of sweep guard….584
Electrical system….587
Electrical system….588
Removal and installation of dashboard assembly….588
Removal and installation of panel assembly….589
90 Diagrams and drawings….591
Hydraulic diagrams and drawings….591
Hydraulic diagrams and drawings….593
Power train hydraulic circuit diagram….593
Work equipment hydraulic circuit diagram (1-spool valve (angle dozer))….594
Work equipment hydraulic circuit diagram (3-spool valve (angle tilt dozer))….595
Work equipment hydraulic circuit diagram (2-spool valve (trimming dozer))….596
Electrical diagrams and drawings….599
Electrical diagrams and drawings….601
Forestry specification, general construction specification….601
Electrical circuit diagram (Serial No. 1003 and up, J10011 and up)….602
Trimming dozer….603
Electrical circuit diagram (2/2)….604
PEN00166-00 – BULLDOZER D68ESS-12 Operation & Maintenance Manual…2
COVER…2
FOREWORD…3
FOREWORD…4
SAFETY INFORMATION…7
INTRODUCTION…9
FRONT/REAR, LEFT/RIGHT DIRECTIONS OF MACHINE…9
NECESSARY INFORMATION…10
PRODUCT IDENTIFICATION NUMBER (PIN)/MACHINE SERIAL NO. PLATE…10
ENGINE SERIAL NO. PLATE…10
POSITION OF SERVICE METER…11
TABLE OF ENTER SERIAL NO. AND DISTRIBUTOR…11
CONTENTS…12
SAFETY…15
SAFETY…16
SAFETY LABELS…18
POSITIONS OF SAFETY PICTOGRAMS…18
SAFETY LABELS…19
GENERAL PRECAUTIONS…22
SAFETY RULES…22
IF PROBLEMS ARE FOUND…22
CLOTHING AND PERSONAL PROTECTIVE ITEMS…22
FIRE EXTINGUISHER AND FIRST AID KIT…22
SAFETY FEATURES…22
KEEP MACHINE CLEAN…23
INSIDE OPERATOR'S COMPARTMENT…23
ALWAYS APPLY LOCK WHEN LEAVING OPERATOR'S SEAT…23
HANDRAILS AND STEPS…24
MOUNTING AND DISMOUNTING…24
NO PEOPLE ON ATTACHMENTS…24
CRUSHING OR CUTTING PREVENTION…24
PREVENTION OF BURNS…25
FIRE PREVENTION…25
ACTION IF FIRE OCCURS…26
WINDOW WASHER LIQUID…26
PRECAUTIONS WHEN USING ROPS (ROLL OVER PROTECTIVE STRUCTURE)…26
PRECAUTIONS FOR ATTACHMENTS…27
UNAUTHORIZED MODIFICATION…27
SAFETY AT WORKSITE…27
WORKING ON LOOSE GROUND…27
DO NOT GO CLOSE TO HIGH-VOLTAGE CABLES…28
ENSURE GOOD VISIBILITY…28
VENTILATION FOR ENCLOSED AREAS…29
CHECKING SIGNALMAN'S SIGNALS AND SIGNS…29
EMERGENCY EXIT FROM OPERATOR'S CAB…29
BE CAREFUL ABOUT ASBESTOS DUST…29
PRECAUTIONS FOR OPERATION…30
STARTING ENGINE…30
CHECKS BEFORE STARTING ENGINE…30
PRECAUTIONS WHEN STARTING…30
PRECAUTIONS IN COLD AREAS…31
OPERATION…32
CHECKS BEFORE OPERATION…32
PRECAUTIONS FOR MOVING MACHINE FORWARD OR IN REVERSE…32
PRECAUTIONS WHEN TRAVELING…32
TRAVELING ON SLOPES…33
PROHIBITED OPERATIONS…33
USING BRAKES…33
PARKING MACHINE…33
TRANSPORTATION…35
LOADING AND UNLOADING…35
SHIPPING…35
BATTERY…36
BATTERY HAZARD PREVENTION…36
STARTING WITH BOOSTER CABLE…37
TOWING…38
WHEN TOWING…38
PRECAUTIONS FOR MAINTENANCE…39
WARNING TAG…39
KEEP WORK PLACE CLEAN AND TIDY…39
APPOINT LEADER WHEN WORKING WITH OTHERS…39
STOP ENGINE BEFORE CARRYING OUT INSPECTION AND MAINTENANCE…39
TWO WORKERS FOR MAINTENANCE WHEN ENGINE IS RUNNING…40
PROPER TOOLS…41
NO UNAUTHORIZED PERSONNEL INTO AREA…41
ATTACHMENTS…41
WORK UNDER THE MACHINE…41
NOISE…41
PRECAUTIONS WHEN USING HAMMER…42
REPAIR WELDING…42
REMOVING BATTERY TERMINAL…42
PRECAUTIONS WHEN USING HIGH-PRESSURE GREASE TO ADJUST TRACK TENSION…42
DO NOT DISASSEMBLE RECOIL SPRING…42
PRECAUTION WITH HIGH-PRESSURE OIL…43
HANDLING HIGH-PRESSURE HOSES…43
WASTE MATERIAL…43
COMPRESSED AIR…44
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…44
OPERATION…45
GENERAL VIEW…46
GENERAL VIEW OF MACHINE…46
GENERAL VIEW OF CONTROLS AND GAUGES…47
EXPLANATION OF COMPONENTS…48
MONITOR PANEL…48
SWITCHES…51
CONTROL LEVERS AND PEDALS…54
FUSE…60
ELECTRIC POWER TAKE-OUT ADAPTER…61
CAP, COVER WITH LOCK…62
DOOR POCKET…63
TOOL BOX…63
OPERATION…64
CHECK BEFORE STARTING ENGINE, ADJUST…64
STARTING ENGINE…76
OPERATIONS AND CHECKS AFTER STARTING ENGINE…80
STOPPING ENGINE…84
MACHINE OPERATION…85
SHIFTING GEARS…88
SHIFTING BETWEEN FORWARD AND REVERSE…89
STEERING MACHINE…91
PRECAUTIONS FOR OPERATION…95
WORK POSSIBLE USING BULLDOZER…97
ADJUSTING POSTURE OF WORK EQUIPMENT…99
PARKING MACHINE…101
CHECK AFTER FINISHING WORK…103
LOCKING…103
TIPS FOR LONGER UNDERCARRIAGE LIFE…104
TRANSPORTATION…107
TRANSPORTATION MEANS…107
PRECAUTIONS WHEN REMOVING WORK EQUIPMENT…107
LOADING, UNLOADING WORK…108
LIFTING MACHINE…112
COLD WEATHER OPERATION…114
PRECAUTIONS FOR LOW TEMPERATURE…114
AFTER COMPLETION OF WORK…115
AFTER COLD WEATHER…115
LONG-TERM STORAGE…116
BEFORE STORAGE…116
DURING STORAGE…116
AFTER STORAGE…116
TROUBLESHOOTING…117
AFTER RUNNING OUT OF FUEL…117
MACHINE TOWING METHOD…117
IF BATTERY IS DISCHARGED…118
OTHER TROUBLE…122
MAINTENANCE…128
GUIDE TO MAINTENANCE…129
OUTLINE OF SERVICE…132
OUTLINE OF OIL, FUEL, COOLANT, AND PERFORMING OIL CLINIC…132
RELATING TO ELECTRIC SYSTEM…134
WEAR PARTS LIST…135
WEAR PARTS LIST…135
RECOMMENDED FUEL, COOLANT, AND LUBRICANT…136
USE OF FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…137
RECOMMENDED BRANDS, RECOMMENDED QUALITY FOR PRODUCTS OTHER THAN KOMATSU GENUINE OIL…138
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…139
TORQUE LIST…139
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…140
SAFETY CRITICAL PARTS…140
MAINTENANCE SCHEDULE CHART…141
MAINTENANCE SCHEDULE CHART…141
SERVICE PROCEDURE…143
WHEN REQUIRED…143
CHECK, CLEAN AND REPLACE AIR CLEANER ELEMENT…143
CLEAN INSIDE OF COOLING SYSTEM…146
CHECK TRACK SHOE TENSION, ADJUST…149
CHECK AND TIGHTEN TRACK SHOE BOLTS…151
CHECK ELECTRICAL INTAKE AIR HEATER…151
REVERSE AND REPLACE END BITS AND CUTTING EDGES…152
CLEAN, CHECK RADIATOR FINS…153
CHECK IDLER OIL LEVEL, ADD OIL…154
ADJUST IDLER CLEARANCE…154
CHECK OIL LEVEL IN DAMPER CASE, ADD AND CHANGE OIL…155
PROCEDURE FOR BLEEDING AIR IN HYDRAULIC SYSTEM…157
PROCEDURE FOR RELEASING INTERNAL PRESSURE OF HYDRAULIC SYSTEM…157
CHECK BEFORE STARTING…158
EVERY 50 HOURS SERVICE…159
DRAIN WATER, SEDIMENT FROM FUEL TANK…159
LUBRICATING…159
EVERY 250 HOURS SERVICE…160
LUBRICATING…160
GREASE EQUALIZER BAR SIDE PIN…161
GREASE EQUALIZER BAR CENTER PIN…161
CHECK OIL LEVEL IN FINAL DRIVE CASE, ADD OIL…162
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…162
CHECK LEVEL OF BATTERY ELECTROLYTE…163
CHECK FAN BELT TENSION, ADJUST…165
CHECK, CLEAN FUEL STRAINER…166
CHECK BRAKE PERFORMANCE…166
EVERY 500 HOURS SERVICE…167
REPLACE FUEL FILTER CARTRIDGE…167
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…168
REPLACE CORROSION RESISTOR CARTRIDGE…169
REPLACE POWER TRAIN OIL FILTER ELEMENT…170
EVERY 1000 HOURS SERVICE…171
CHANGE OIL IN POWER TRAIN CASE, CLEAN STRAINERS (POWER TRAIN PUMP STRAINER, SCAVENGING PUMP STRAINER)…171
CHANGE OIL IN FINAL DRIVE CASE…173
CLEAN BREATHER…173
GREASE UNIVERSAL JOINT…174
GREASE TENSION PULLEY ASSEMBLY…175
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…175
CHECK PLAY OF TURBOCHARGER ROTOR…175
EVERY 2000 HOURS SERVICE…176
CHANGE OIL IN HYDRAULIC TANK, REPLACE OIL FILTER CARTRIDGE AND CLEAN SUCTION STRAINER…176
CLEAN, CHECK TURBOCHARGER…177
CHECK VIBRATION DAMPER…177
CHECK ALTERNATOR, STARTING MOTOR…177
CHECK ENGINE VALVE CLEARANCE, ADJUST…177
EVERY 4000 HOURS SERVICE…178
CHECK WATER PUMP…178
SPECIFICATIONS…179
SPECIFICATIONS…180
ATTACHMENTS, OPTIONS…181
GENERAL PRECAUTIONS…182
PRECAUTIONS RELATED TO SAFETY…182
HANDLING TOWING WINCH…183
EXPLANATION OF COMPONENTS…183
OPERATION…185
SERVICE PROCEDURE…191
SPECIFICATIONS…192
HANDLING TRIMMING DOZER…193
GENERAL VIEW…193
EXPLANATION OF COMPONENTS…194
OPERATION…196
MAINTENANCE…199
SPECIFICATIONS…202
INDEX…203
SEN01128-06 – BULLDOZER D68ESS-12 Shop Manual…206
Cover…206
00 Index and foreword…208
Index…208
Composition of shop manual…209
Table of contents…211
Foreword and general information…218
Safety notice…219
How to read the shop manual…224
Explanation of terms for maintenance standard…226
Handling of connectors newly used for engines…237
How to read electric wire code…240
Precautions when carrying out operation…243
Method of disassembling and connecting push-pull type coupler…246
Standard tightening torque table…249
Conversion table…253
01 Specification…260
Specification and technical data…260
Specification and technical data…261
Specification drawing…261
Specifications…263
Weight table…267
Table of fuel, coolant and lubricants…269
10 Structure, function andmaintenance standard…272
Engine and cooling system…272
Engine and cooling system…273
Radiator, power train, oil cooler…273
Engine control…275
Power train, Part 1…278
Power train, Part 1…279
Power train system…279
Power train skeleton…280
Power train unit…281
Power train hydraulic piping diagram…282
Damper, universal joint…283
Torque converter and PTO…286
Transmission control…291
Transmission…292
Transmission control valve…301
Main relief valve…307
Lubrication relief valve…310
Steering and brake control…311
Power train, Part 2…314
Power train, Part 2…315
Bevel gear shaft, steering clutch and brake…315
Brake valve…325
Scavenging pump strainer…330
Power train oil strainer…331
Power train oil filter…332
Final drive…333
Undercarriage and frame…340
Undercarriage and frame…341
Main frame…341
Suspension…343
Track frame…346
Recoil spring…347
Idler…349
Track roller…350
Carrier roller…351
Track shoe…353
Hydraulic system, Part 1…356
Hydraulic system, Part 1…357
Work equipment hydraulic piping diagram…357
PPC control piping diagram…361
Work equipment control…362
Hydraulic tank and filter…365
Hydraulic pump…367
Power train lubrication pump…368
PPC valve (for steering)…369
PPC charge valve…374
Hydraulic system, Part 2…378
Hydraulic system, Part 2…379
1-spool valve 1…379
CLSS…385
Functions, operation of valve…387
Suction valve…395
3-spool valve 1…397
CLSS…404
Functions, operation of valve…406
Suction valve…415
Work equipment…418
Work equipment…419
Work equipment…419
Cutting edge, end bit…429
Work equipment cylinder…431
Electrical system…434
Electrical system…435
Engine control…435
Machine monitor system…436
Sensors…439
20 Standard value table…444
Standard service value table…444
Standard service value table…445
Standard value table for engine…445
Standard value table for chassis…446
Standard value table for electrical system…451
30 Testing and adjusting…454
Testing and adjusting…454
Testing and adjusting…455
Tools for testing, adjusting, and troubleshooting…455
Measuring blow-by pressure…456
Measuring exhaust color…457
Measuring engine oil pressure…458
Measuring engine speed…459
Testing fan belt tension…460
Measuring speed at torque…461
Adjusting fuel control linkage…462
Adjusting steering/directional lever, gearshift lever, and parking brake lever…464
Adjusting brake pedal linkage…467
Adjusting work equipment lock lever…468
Measuring power train hydraulic pressure…469
Measuring and adjusting work equipment oil pressure…472
Measuring leakage inside cylinder…473
Bleeding air from hydraulic cylinder…473
40 Troubleshooting…476
General information on troubleshooting…476
General information on troubleshooting…477
Points to remember when troubleshooting…477
How to proceed troubleshooting…478
Connector types and mounting locations…480
Connector pin arrangement diagram…481
How to distinguish wire code…483
Wiring table for connector pin numbers…487
T-adapter box and T-adapter table…520
How to follow the troubleshooting flow diagrams…523
Troubleshooting of electrical system (E-mode)…526
Troubleshooting of electrical system (E-mode)…527
Table of failure modes and causes (Electrical system)…527
Electrical circuit diagram for each system…529
E-1 Starting motor is not cranked when starting switch is turned to ON…537
E-2 Lamps do not light up…543
Troubleshooting of hydraulic and mechanical system (H-mode)…548
Troubleshooting of hydraulic and mechanical system (H-mode)…551
Table of failure modes and causes (hydraulic, mechanical system)…551
H-1 Brake does not work…553
H-2 Machine does not turn (can travel in a straight line)…554
H-3 Overruns when turning…555
H-4 Can turn in only one direction (when steering lever is operated)…555
H-5 Excessive time lag…556
H-6 Machine can travel in only one direction (forward or reverse)…556
H-7 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd)…557
H-8 Machine does not move in any speed range…559
H-9 Power train oil temperature rises too high…561
H-10 Drawbar pull is weak, travel speed is slow…563
H-11 Abnormal noise is generated from around hydraulic pump…565
H-12 Work equipment speed is slow or lacks power…565
H-13 No work equipment moves…566
H-14 Blade lift or tilt cylinder speed is slow or lacks power…566
H-15 Blade angle cylinder speed is slow or lacks power…567
H-16 Hydraulic drift of blade lift is excessive…567
H-17 Hydraulic drift of blade tilt is excessive…568
H-18 Hydraulic drift of blade angle is excessive…568
Troubleshooting of machine monitor system (M-mode)…570
Troubleshooting of machine monitor system (M-mode)…571
Table of failure modes and causes (machine monitor system)…571
Electrical circuit diagrams for each system…573
M-1 Caution item lights up…581
M-2 Gauge is abnormal…585
M-3 Service meter does not move after engine is started…593
M-4 Monitor panel lighting does not light up (front lamps are normal)…594
50 Disassembly and assembly…598
General information on disassembly and assembly…598
General information on disassembly and assembly…599
How to read this manual…599
Coating materials list…601
Special tool list…604
Sketches of special tools…608
Engine and cooling system…612
Engine and cooling system…613
Removal and installation of engine assembly…613
Removal and installation of…615
Removal and installation of…617
Removal and installation of…620
Removal and installation of fuel tank assembly…621
Removal and installation of…622
Power train…626
Power train…628
Removal and installation of PTO, torque converter and transmission assembly…628
Disconnection and connection of PTO, torque converter and transmission assembly…632
Disassembly and assembly of…634
Disassembly and assembly of…639
Disassembly and assembly of…643
Removal and installation of …660
Disassembly and assembly of …661
Removal and installation of transmission control valve assembly…662
Disassembly and assembly of transmission control valve assembly…663
Removal and installation of steering clutch and brake assembly…665
Disassembly and assembly of steering clutch and brake assembly…666
Removal and installation of bevel gear and bevel gear shaft (Clutch and brake model)…673
Removal and installation of brake valve assembly…679
Disassembly and assembly of brake valve assembly…680
Removal and installation of scavenging pump assembly…683
Removal and installation of power train and lubricating oil pump assembly…684
Removal and installation of final drive assembly…686
Disassembly and assembly of final drive assembly…687
Undercarriage and frame…700
Undercarriage and frame…701
Removal and installation of track frame assembly…701
Removal and installation of recoil spring assembly…703
Disassembly and assembly of recoil spring assembly…704
Removal and installation of idler assembly…707
Disassembly and assembly of idler assembly…708
Removal and installation of track roller assembly…712
Disassembly and assembly of track roller assembly…713
Removal and installation of carrier roller assembly…716
Disassembly and assembly of carrier roller assembly…717
Removal and installation of track shoe assembly…719
Overall disassembly and assembly of track shoe assembly…720
Field disassembly and assembly of one link…736
Removal and installation of pivot shaft assembly…743
Removal and installation of equalizer bar assembly…745
Removal and installation of equalizer bar side bushing…747
Removal installation of segment teeth…748
Hydraulic system…750
Hydraulic system…751
Removal and installation of work equipment pump assembly…751
Removal and installation of work equipment control valve assembly…752
Disassembly and assembly of work equipment control valve assembly…754
Removal and installation of steering PPC valve assembly…758
Disassembly and assembly of steering PPC valve assembly…759
Removal and installation of suction valve assembly…762
Removal and installation of blade angle cylinder assembly…763
Removal and installation of blade tilt cylinder assembly…764
Removal and installation of blade lift cylinder assembly…765
Disassembly and assembly of hydraulic cylinder assembly…766
Work equipment…772
Work equipment…773
Removal and installation of work equipment assembly…773
Disassembly and assembly of work equipment assembly…779
Cab and its attachments…784
Cab and its attachments…785
Removal and installation of floor frame assembly…785
Removal and installation of sweep guard…789
Electrical system…792
Electrical system…793
Removal and installation of dashboard assembly…793
Removal and installation of panel assembly…794
90 Diagrams and drawings…796
Hydraulic diagrams and drawings…796
Hydraulic diagrams and drawings…798
Power train hydraulic circuit diagram…798
Work equipment hydraulic circuit diagram (1-spool valve (angle dozer))…799
Work equipment hydraulic circuit diagram (3-spool valve (angle tilt dozer))…800
Work equipment hydraulic circuit diagram (2-spool valve (trimming dozer))…801
Electrical diagrams and drawings…804
Electrical diagrams and drawings…806
Forestry specification, general construction specification…806
Electrical circuit diagram (Serial No. 1003 and up, J10011 and up)…807
Trimming dozer…808
Electrical circuit diagram (2/2)…809
Komatsu BULLDOZERS D68ESS Repair Service Manual