![SEN01135-00 10 Structure, function and maintenance standard
4 D68ESS-12
Engine control 1
1. Decelerator pedal
2. Throttle lever
3. Clutch
4. Cable
5. Fuel injection pump
Lever positions
[1] Low idle
[2] High idle
Outline
q The engine speed is controlled by throttle lever
(2) or decelerator pedal (1).](https://image.slidesharecdn.com/komatsud68ess-12dozerbulldozerservicerepairmanualsnj10001andup-200916013934/85/Komatsu-d68-ess-12-dozer-bulldozer-service-repair-manual-sn-j10001-and-up-26-320.jpg)
Komatsu d68 ess 12 dozer bulldozer service repair manual (sn j10001 and up)
- 2. SEN01130-05 00 Index and foreword 4 D68ESS-12 Table of contents 1 00 Index and foreword Index SEN01130-05 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information SEN01131-02 Safety notice............................................................................................................................ 2 How to read the shop manual.................................................................................................. 7 Explanation of terms for maintenance standard ...................................................................... 9 Handling of electric equipment and hydraulic component ....................................................... 11 Handling of connectors newly used for engines ...................................................................... 20 How to read electric wire code................................................................................................. 23 Precautions when carrying out operation ................................................................................ 26 Method of disassembling and connecting push-pull type coupler ........................................... 29 Standard tightening torque table.............................................................................................. 32 Conversion table...................................................................................................................... 36 01 Specification Specification and technical data SEN01133-00 Specification and technical data.................................................................................................. 2 Specification drawing............................................................................................................... 2 Specifications........................................................................................................................... 4 Weight table............................................................................................................................. 8 Table of fuel, coolant and lubricants ........................................................................................ 10 10 Structure, function and maintenance standard Engine and cooling system SEN01135-00 Engine and cooling system ......................................................................................................... 2 Radiator, power train, oil cooler ............................................................................................... 2 Engine control.......................................................................................................................... 4 Power train, Part 1 SEN01136-00 Power train, Part 1....................................................................................................................... 2 Power train system .................................................................................................................. 2 Power train skeleton ................................................................................................................ 3 Power train unit........................................................................................................................ 4 Power train hydraulic piping diagram....................................................................................... 5 Damper, universal joint ............................................................................................................ 6 Torque converter and PTO....................................................................................................... 9 Transmission control................................................................................................................ 14 Transmission............................................................................................................................ 15 Transmission control valve ...................................................................................................... 24 Main relief valve....................................................................................................................... 30 Lubrication relief valve............................................................................................................. 33 Steering and brake control....................................................................................................... 34 Power train, Part 2 SEN01137-00 Power train, Part 2....................................................................................................................... 2 Bevel gear shaft, steering clutch and brake............................................................................. 2 Brake valve.............................................................................................................................. 12 Scavenging pump strainer....................................................................................................... 17 Power train oil strainer............................................................................................................. 18 Power train oil filter .................................................................................................................. 19 Final drive ................................................................................................................................ 20
- 3. 00 Index and foreword SEN01130-05 D68ESS-12 5 Undercarriage and frame SEN01138-00 Undercarriage and frame ............................................................................................................ 2 Main frame............................................................................................................................... 2 Suspension.............................................................................................................................. 4 Track frame.............................................................................................................................. 7 Recoil spring............................................................................................................................ 8 Idler.......................................................................................................................................... 10 Track roller............................................................................................................................... 11 Carrier roller............................................................................................................................. 12 Track shoe............................................................................................................................... 14 Hydraulic system, Part 1 SEN01139-00 Hydraulic system, Part 1 ............................................................................................................. 2 Work equipment hydraulic piping diagram .............................................................................. 2 PPC control piping diagram..................................................................................................... 6 Work equipment control........................................................................................................... 7 Hydraulic tank and filter ........................................................................................................... 10 Hydraulic pump........................................................................................................................ 12 Power train lubrication pump................................................................................................... 13 PPC valve (for steering) .......................................................................................................... 14 PPC charge valve.................................................................................................................... 19 Hydraulic system, Part 2 SEN01140-01 Hydraulic system, Part 2 ............................................................................................................. 2 1-spool valve Main control valve.................................................................................................................... 2 CLSS ....................................................................................................................................... 8 Functions, operation of valve................................................................................................... 10 Suction valve ........................................................................................................................... 18 3-spool valve Main control valve.................................................................................................................... 20 CLSS ....................................................................................................................................... 27 Functions, operation of valve................................................................................................... 29 Suction valve ........................................................................................................................... 38 Work equipment SEN01141-00 Work equipment .......................................................................................................................... 2 Work equipment ...................................................................................................................... 2 Cutting edge, end bit ............................................................................................................... 12 Work equipment cylinder ......................................................................................................... 14 Electrical system SEN01142-00 Electrical system ......................................................................................................................... 2 Engine control.......................................................................................................................... 2 Machine monitor system.......................................................................................................... 3 Sensors ................................................................................................................................... 6 20 Standard value table Standard service value table SEN01499-01 Standard service value table ....................................................................................................... 2 Standard value table for engine............................................................................................... 2 Standard value table for chassis.............................................................................................. 3 Standard value table for electrical system ............................................................................... 8
- 4. SEN01130-05 00 Index and foreword 6 D68ESS-12 30 Testing and adjusting Testing and adjusting SEN01501-01 Testing and adjusting................................................................................................................... 2 Tools for testing, adjusting, and troubleshooting...................................................................... 2 Measuring blow-by pressure.................................................................................................... 3 Measuring exhaust color.......................................................................................................... 4 Measuring engine oil pressure................................................................................................. 5 Measuring engine speed ......................................................................................................... 6 Testing fan belt tension............................................................................................................ 7 Measuring speed at torque converter stall............................................................................... 8 Adjusting fuel control linkage................................................................................................... 9 Adjusting steering/directional lever, gearshift lever, and parking brake lever .......................... 11 Adjusting brake pedal linkage.................................................................................................. 14 Adjusting work equipment lock lever ....................................................................................... 15 Measuring power train hydraulic pressure............................................................................... 16 Measuring and adjusting work equipment oil pressure............................................................ 19 Measuring leakage inside cylinder........................................................................................... 20 Bleeding air from hydraulic cylinder......................................................................................... 20 40 Troubleshooting General information on troubleshooting SEN01503-01 General information on troubleshooting ...................................................................................... 2 Points to remember when troubleshooting .............................................................................. 2 How to proceed troubleshooting.............................................................................................. 3 Connector types and mounting locations................................................................................. 5 Connector pin arrangement diagram....................................................................................... 6 How to distinguish wire code ................................................................................................... 8 Wiring table for connector pin numbers ................................................................................... 12 T-adapter box and T-adapter table .......................................................................................... 45 How to follow the troubleshooting flow diagrams..................................................................... 48 Troubleshooting of electrical system (E-mode) SEN01504-01 Troubleshooting of electrical system (E-mode) ........................................................................... 2 Table of failure modes and causes (Electrical system)............................................................ 2 Electrical circuit diagram for each system ............................................................................... 4 E-1 Starting motor is not cranked when starting switch is turned to ON.................................. 12 E-2 Lamps do not light up........................................................................................................ 18 Troubleshooting of hydraulic and mechanical system (H-mode) SEN01505-00 Troubleshooting of hydraulic and mechanical system (H-mode)................................................. 4 Table of failure modes and causes (hydraulic, mechanical system)........................................ 4 H-1 Brake does not work ......................................................................................................... 6 H-2 Machine does not turn (can travel in a straight line) ......................................................... 7 H-3 Overruns when turning...................................................................................................... 8 H-4 Can turn in only one direction (when steering lever is operated)...................................... 8 H-5 Excessive time lag ............................................................................................................ 9 H-6 Machine can travel in only one direction (forward or reverse) .......................................... 9 H-7 Machine does not move (when engine is started and lever is shifted to 2nd or 3rd) ........ 10 H-8 Machine does not move in any speed range .................................................................... 12 H-9 Power train oil temperature rises too high ........................................................................ 14 H-10 Drawbar pull is weak, travel speed is slow ..................................................................... 16 H-11 Abnormal noise is generated from around hydraulic pump............................................. 18 H-12 Work equipment speed is slow or lacks power............................................................... 18 H-13 No work equipment moves ............................................................................................. 19 H-14 Blade lift or tilt cylinder speed is slow or lacks power ..................................................... 19 H-15 Blade angle cylinder speed is slow or lacks power......................................................... 20 H-16 Hydraulic drift of blade lift is excessive ........................................................................... 20 H-17 Hydraulic drift of blade tilt is excessive ........................................................................... 21 H-18 Hydraulic drift of blade angle is excessive ...................................................................... 21
- 5. 00 Index and foreword SEN01130-05 D68ESS-12 7 Troubleshooting of machine monitor system (M-mode) SEN01506-01 Troubleshooting of machine monitor system (M-mode).............................................................. 2 Table of failure modes and causes (machine monitor system)................................................ 2 Electrical circuit diagrams for each system ............................................................................. 4 M-1 Caution item lights up....................................................................................................... 12 M-2 Gauge is abnormal ........................................................................................................... 16 M-3 Service meter does not move after engine is started ....................................................... 24 M-4 Monitor panel lighting does not light up (front lamps are normal)..................................... 25 50 Disassembly and assembly General information on disassembly and assembly SEN01508-00 General information on disassembly and assembly.................................................................... 2 How to read this manual.......................................................................................................... 2 Coating materials list ............................................................................................................... 4 Special tool list......................................................................................................................... 7 Sketches of special tools......................................................................................................... 11 Engine and cooling system SEN01509-00 Engine and cooling system ......................................................................................................... 2 Removal and installation of engine assembly ......................................................................... 2 Removal and installation of radiator and guard assembly....................................................... 4 Removal and installation of radiator assembly ........................................................................ 6 Removal and installation of hydraulic oil cooler assembly ...................................................... 9 Removal and installation of fuel tank assembly....................................................................... 10 Removal and installation of damper assembly ........................................................................ 11 Power train SEN01510-02 Power train.................................................................................................................................. 3 Removal and installation of PTO, torque converter and transmission assembly..................... 3 Disconnection and connection of PTO, torque converter and transmission assembly............ 7 Disassembly and assembly of PTO assembly......................................................................... 9 Disassembly and assembly of torque converter assembly...................................................... 14 Disassembly and assembly of TORQFLOW transmission assembly...................................... 18 Removal and installation of torque converter main relief valve assembly ............................... 35 Disassembly and assembly of torque converter main relief valve assembly........................... 36 Removal and installation of transmission control valve assembly........................................... 37 Disassembly and assembly of transmission control valve assembly ...................................... 38 Removal and installation of steering clutch and brake assembly ............................................ 40 Disassembly and assembly of steering clutch and brake assembly........................................ 41 Removal and installation of bevel gear and bevel gear shaft (Clutch and brake model)......... 48 Removal and installation of brake valve assembly.................................................................. 54 Disassembly and assembly of brake valve assembly ............................................................. 55 Removal and installation of scavenging pump assembly ........................................................ 58 Removal and installation of power train and lubricating oil pump assembly ........................... 59 Removal and installation of final drive assembly..................................................................... 61 Disassembly and assembly of final drive assembly ................................................................ 62 Undercarriage and frame SEN01511-01 Undercarriage and frame ............................................................................................................ 2 Removal and installation of track frame assembly .................................................................. 2 Removal and installation of recoil spring assembly................................................................. 4 Disassembly and assembly of recoil spring assembly ............................................................ 5 Removal and installation of idler assembly ............................................................................. 8 Disassembly and assembly of idler assembly ......................................................................... 9 Removal and installation of track roller assembly ................................................................... 13 Disassembly and assembly of track roller assembly ............................................................... 14 Removal and installation of carrier roller assembly ................................................................. 17 Disassembly and assembly of carrier roller assembly............................................................. 18 Removal and installation of track shoe assembly.................................................................... 20
- 6. SEN01130-05 00 Index and foreword 8 D68ESS-12 Overall disassembly and assembly of track shoe assembly.................................................... 21 Field disassembly and assembly of one link............................................................................ 37 Removal and installation of pivot shaft assembly .................................................................... 44 Removal and installation of equalizer bar assembly................................................................ 46 Removal and installation of equalizer bar side bushing........................................................... 48 Removal installation of segment teeth..................................................................................... 49 Hydraulic system SEN01512-01 Hydraulic system......................................................................................................................... 2 Removal and installation of work equipment pump assembly ................................................. 2 Removal and installation of work equipment control valve assembly...................................... 3 Disassembly and assembly of work equipment control valve assembly ................................. 5 Removal and installation of steering PPC valve assembly...................................................... 9 Disassembly and assembly of steering PPC valve assembly ................................................. 10 Removal and installation of suction valve assembly................................................................ 13 Removal and installation of blade angle cylinder assembly .................................................... 14 Removal and installation of blade tilt cylinder assembly.......................................................... 15 Removal and installation of blade lift cylinder assembly.......................................................... 16 Disassembly and assembly of hydraulic cylinder assembly .................................................... 17 Work equipment SEN01513-01 Work equipment .......................................................................................................................... 2 Removal and installation of work equipment assembly ........................................................... 2 Disassembly and assembly of work equipment assembly....................................................... 8 Cab and its attachments SEN01514-00 Cab and its attachments.............................................................................................................. 2 Removal and installation of floor frame assembly ................................................................... 2 Removal and installation of sweep guard ................................................................................ 6 Electrical system SEN01515-01 Electrical system ......................................................................................................................... 2 Removal and installation of dashboard assembly ................................................................... 2 Removal and installation of panel assembly............................................................................ 3 90 Diagrams and drawings Hydraulic diagrams and drawings SEN01144-00 Hydraulic diagrams and drawings ............................................................................................... 3 Power train hydraulic circuit diagram....................................................................................... 3 Work equipment hydraulic circuit diagram (1-spool valve (angle dozer)) ................................ 5 Work equipment hydraulic circuit diagram (3-spool valve (angle tilt dozer)) ........................... 7 Work equipment hydraulic circuit diagram (2-spool valve (trimming dozer)) ........................... 9 Electrical diagrams and drawings SEN01145-01 Electrical diagrams and drawings................................................................................................ 3 Forestry specification, general construction specification Electrical circuit diagram (Serial No. 1001 – 1002, J10001 – J10010).................................... 3 Electrical circuit diagram (Serial No. 1003 and up, J10011 and up) ........................................ 5 Trimming dozer Electrical circuit diagram.......................................................................................................... 7
- 7. D68ESS-12 1 SEN01131-02 BULLDOZER 1SHOP MANUAL D68ESS-12 Machine model Serial number D68ESS-12 1001 and up J10001 and up 00 Index and foreword 1 Foreword and general information Safety notice ................................................................................................................................................... 2 How to read the shop manual......................................................................................................................... 7 Explanation of terms for maintenance standard ............................................................................................. 9 Handling of electric equipment and hydraulic component .............................................................................11 Handling of connectors newly used for engines ........................................................................................... 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36
- 8. SEN01131-02 00 Index and foreword 2 D68ESS-12 (Rev. 2007/03)Safety notice 1 Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situa- tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. 1) Before carrying out any greasing or repairs, read all the safety plates stuck to the machine. For the locations of the safety plates and detailed explanation of precautions, see the Operation and Main- tenance Manual. 2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working. 3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing. q Always wear safety glasses when hit- ting parts with a hammer. q Always wear safety glasses when grinding parts with a grinder, etc. 4) When carrying out any operation with 2 or more workers, always agree on the oper- ating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator's compartment. 5) Only qualified workers must carry out work and operation which require license or qualification. 6) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, fork- lift, service car, etc. 7) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work. 8) Before starting work, warm up your body thoroughly to start work under good condi- tion. 2. Preparations for work 1) Before adding oil or making any repairs, park the machine on hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers 6 Safety check before starting work 7 Wearing protective goggles (for cleaning or grinding work) 8 Wearing shielding goggles and protectors (for welding work) 9 Good physical condition and preparation 10 Precautions against work which you are not used to or you are used to too much
- 9. 00 Index and foreword SEN01131-02 D68ESS-12 3 3) When disassembling or assembling, sup- port the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad- ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing compo- nents of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wir- ing. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electri- cal parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be dam- aged by contact with other parts when the machine is operated. 11) When installing high pressure hoses, make sure that they are not twisted. Dam- aged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate vio- lently or rotate at high speed, be particu- larly careful to check that they are installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are cor- rectly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accord- ingly, open the windows and doors to ven- tilate well.
- 10. D68ESS-12 1 SEN01133-00 BULLDOZER 1SHOP MANUAL D68ESS-12 Machine model Serial number D68ESS-12 1001 and up J10001 and up 01 Specification 1 Specification and technical data Specification and technical data...................................................................................................................... 2 Specification drawing ........................................................................................................................... 2 Specifications ....................................................................................................................................... 4 Weight table ......................................................................................................................................... 8 Table of fuel, coolant and lubricants................................................................................................... 10
- 11. SEN01133-00 01 Specification 2 D68ESS-12 Specification and technical data 1 Specification drawing 1 Forestry specification Angle dozer (Mechanical angle) Angle tiltdozer (Power angle)
- 12. 01 Specification SEN01133-00 D68ESS-12 3 General construction specification Angle dozer (Mechanical angle) Trimming dozer
- 13. SEN01133-00 01 Specification 4 D68ESS-12 Specifications 1 Machine name and type Forestry specification General construction specification Trimming dozer Serial number 1001 and up J10001 and up 1005 and up Weight Operating weight kg • Bare tractor 14,280 14,150 — • With angle tiltdozer, sweep guard, winch 18,800 — — • With angle dozer, sweep guard, winch 19,100 — — • With angle dozer — 17,350 — • With trimming dozer — — 17,600 • With trimming dozer, ROPS cab — — 17,860 Performance Min. turning radius m 2.8 2.7 2.7 Gradeability deg 30 30 30 Stability (front, rear, left, right) deg 35 35 35 Speedranges Forward 1st 3.4 3.4 3.4 Forward 2nd km/h 5.8 5.8 5.8 Forward 3rd 9.0 9.0 9.0 Reverse 1st 4.4 4.4 4.4 Reverse 2nd km/h 7.6 7.6 7.6 Reverse 3rd 11.3 11.3 11.3 Groundpressure Bare tractor kPa {kg/cm2 } 39 {0.40} 45 {0.46} — Angle tiltdozer, winch, sweep guard 52 {0.53} — — Angle dozer, winch, sweep guard 52 {0.53} — — With angle dozer — 56 {0.57} — With trimming dozer — — 61.4 {0.63} With trimming dozer, ROPS cab — — 62.3 {0.64} Dimensions Overalllength • Bare tractor mm 4,100 4,100 — • With angle tiltdozer, winch 6,120 — — • With angle dozer, winch 6,280 — — • With angle dozer — 5,415 — • With trimming dozer — — 5,855 Overallwidth • Bare tractor mm 2,535 2,535 — • With angle tiltdozer 3,275 — — • With angle dozer 3,970 3,970 — • With trimming dozer — — 3,020 Overallheight • To tip of exhaust pipe mm 2,780 2,715 — • To top of operator’s compartment 2,305 2,305 — • To top of sweep guard 3,135 3,140 — • With trimming dozer, ROPS cab (excluding antenna) — — 3,070 • With trimming dozer, cab (excluding antenna) — — 2,990 Track gauge mm 1,925 1,925 1,925 Length of track on ground 2,930 2,725 2,725 Width of track shoe (standard) 610 560 510 Min. ground clearance (To bottom of undercover) 390 390 390
- 14. 01 Specification SEN01133-00 D68ESS-12 5 Machine name and type Forestry specification General construction specification Trimming dozer Serial number 1001 and up J10001 and up 1005 and up Engine Model S6D114E-1A Type 4-cycle, water cooled, inline vertical type direct injection with turbocharger No. of cylinder – bore × stroke mm 6 – 114 × 135 Piston displacement l {cc} 8.27 {8,270} Performance Rated horsepower kW/rpm {HP/rpm} 116/1,850 {155/1,850} Max. torque Nm/rpm {kgm/rpm} 824/1,300 {84/1,300} High idle rpm 2,000 Low idle rpm 890 Min. fuel consumption ratio g/kWh {g/HPh} 220 {163} Starting motor 24 V, 7.5 kW Alternator 24 V, 35 A Battery 12 V, 200 Ah × 2 Radiator core type D-6 Powertrainsystem Torque converter 3-element, 1-stage, 1 phase Transmission Planetary gear type, multiple disc clutch, hydraulically actuated, lubri- cation gear pump, force feed, forward 3-speed, reverse 3-speed, manual mechanical type Bevel gear shaft Spiral bevel gear, force feed lubrication gear pump Steering clutch Wet type multiple disc, spring boosted, hand operated, hydraulically actuated Steering brake Wet type, multiple disc, spring boosted, hand and foot operated, hydraulically actuated Final drive 2-stage spur gear reduction, splash type lubrication Undercarriage Suspension Semi-rigid, floating beam Carrier roller (each side) 2 Track roller (each side) 7 6 Track shoe 610 mm Assembly type, single grouser, on each side, pitch: 203.2 mm — — Track shoe 560 mm — Assembly type, single grouser, on each side, pitch: 203.2 mm — Track shoe 510 mm — — Assembly type, triple grouser, on each side, pitch: 203.2 mm Power train, lubrication pump Gear type (SAL(2)–040+040) PPC pump Gear type (SBR(1)-08) Max. discharge pressure: 3.0 MPa {31 kg/cm2 } Theoretical discharge amount: 17.3 l/min/2,164 rpm
- 15. SEN01133-00 01 Specification 6 D68ESS-12 Machine name and type Forestry specification General construction specification Trimming dozer Serial number 1001 and up J10001 and up 1005 and up Workequipmenthydraulicsystem Hydraulic pump Gear type (SAL 63) Permissible peak pressure: 24 MPa {250 kg/cm2 } Maincontrolvalve Type 1 spool type — • For blade lift Type 3-spool type (1 spool type for angle dozer) — — • For blade lift • For blade tilt • For blade angle Type — — 2-spool type• For blade lift • For blade incline Hydrauliccylinder Type Reciprocal type Dimensionsof bladeliftcylinder Cylinder bore mm 110 110 Outside diameter of piston rod 55 55 Piston stroke 469 505 Max. distance between pins 1,322 1,394 Min. distance between pins 853 889 Dimensionsof bladetiltcylinder Cylinder bore mm 130 — — Outside diameter of piston rod 70 Piston stroke 190 Max. distance between pins 1,226 Min. distance between pins 1,036 Dimensionsof bladeanglecylinder Cylinder bore mm 100 — — Outside diameter of piston rod 60 Piston stroke 469 Max. distance between pins 1,349 Min. distance between pins 880 Dimensionof trimmingcylinder Cylinder bore mm — — 110 Outside diameter of piston rod 55 Piston stroke 460 Max. distance between pins 1,334 Min. distance between pins 874 Hydraulic tank Box type (externally installed control valve) Workequipment (angletiltdozer) Type Hydraulic angle tiltdozer Blade support method Frame type — Perfor- mance Max. lifting height (from ground) mm 1,055 — —Max. lowering depth (from ground) mm 560 Max. tilt mm 510 Dimen- sions Blade width mm 3,275 — —Blade height mm 1,200 Blade cutting angle deg 57
- 16. 01 Specification SEN01133-00 D68ESS-12 7 Machine name and type Forestry specification General construction specification Trimming dozer Serial number 1001 and up J10001 and up 1005 and up Workequipment (angledozer) Type Mechanical angle Blade support method Frame type — Perfor- mance Max. lifting height (from ground) mm 1,205 1,130 —Max. lowering depth (from ground) mm 535 540 Max. tilt mm 400 Dimen- sions Blade width mm 3,970 —Blade height mm 950 Blade cutting angle deg 55 Workequipment (trimmingdozer) Type Trimming dozer Blade support method — — Frame type Performance Max. lifting height (from ground) mm — — 1,655 Max. lowering depth (from ground) mm 735 Degree of blade inclining Front direction deg 45 Rear direction 26 Dimen- sions Blade width mm 3,020 Blade height mm 960
- 17. SEN01133-00 01 Specification 8 D68ESS-12 Weight table 1 k This weight table is a guide for use when transporting or handling components. Unit: kg Machine Model Forestry specification General construction specification Trimming dozer Serial Numbers 1001 and up J10001 and up 1005 and up Engine, damper assembly 840 • Engine assembly 797 • Damper assembly 35 • Parts mounted to engine (wiring) 8 Radiator assembly (including oil cooler) 140 • Oil cooler assembly (for hydraulic oil) 5 • Fuel tank assembly 151 Transmission assembly 465 • Transmission valve assembly 15 • Main relief valve assembly 7 Torque converter, PTO assembly 320 • Steering clutch and brake assembly 1,235 Final drive assembly (each side) 741 Sprocket assembly (each side) 15 × 5 Hull frame assembly 1,010 Track group assembly (each side) 1,398 1,398 • Track frame 534 510 • Idler assembly (each side) 172 172 • Track roller assembly (single: 1) 54 × 5 54 × 5 • Track roller assembly (double: 1) 61 × 2 61 × 2 • Carrier roller assembly (1) 27 × 2 27 × 2 Track shoe assembly (each side) (single) (610 mm, wet type) 1,493 — — Track shoe assembly (each side) (single) (560 mm, wet type) — 1,365 — Track shoe assembly (each side) (triple) (510 mm, wet type) — — 2,770 Pivot shaft (each side) 78 Equalizer bar 85 Hydraulic tank assembly 44 44 Main control valve • Lift 16 16 • Lift + tilt + angle 32 — Engine underguard 45 Transmission underguard 22 Operator's seat 27
- 18. 01 Specification SEN01133-00 D68ESS-12 9 Angle tiltdozer assembly 2,355 — — • Blade 1,010 • U-frame 1,005 • Tilt cylinder assembly 78 • Angle cylinder 52 × 2 Blade lift cylinder assembly 48 × 2 Power train pump assembly 20 Hydraulic pump assembly 11 Floor frame assembly 310 Sweep guard assembly 548 Winch assembly (with wire) 1,520 — Angel dozer assembly 2,660 —• Blade 910 • C-frame 1,012 Trimming dozer — — 2,550 • Trimming dozer cylinder assembly 48 x 2 Unit: kg Machine Model Forestry specification General construction specification Trimming dozer Serial Numbers 1001 and up J10001 and up 1005 and up
- 19. SEN01133-00 01 Specification 10 D68ESS-12 Table of fuel, coolant and lubricants 1 a For details of notes (Notes 1 and 2...) in the table, see Operation and Maintenance Manual. a Although SAE10W30DH and SAE15W40DH are specified to be used as engine oil for engine oil pan, SAE10W30 (API CH4, CI-4) and SAE15W40 (API CH4, CI-4) can be used instead respectively.
- 20. 01 Specification SEN01133-00 D68ESS-12 11 Unit: l Supply point Specified capacity Refill capacity Engine oil pan 23 19 Damper case 1.3 1.3 Idler (each of right and left) 0.22 0.22 Hydraulic oil system 73 48 Power train case 100 75 Final drive case (each of right and left) 32 28.5 Fuel tank 315 — Cooling system (including sub-tank) 44 —
- 21. 12 SEN01133-00 D68ESS-12 Bulldozer Form No. SEN01133-00 © 2006 KOMATSU All Rights Reserved Printed in Japan 06-06 (01)
- 22. D68ESS-12 1 SEN01135-00 BULLDOZER 1SHOP MANUAL D68ESS-12 Machine model Serial number D68ESS-12 1001 and up J10001 and up 10 Structure, function and maintenance standard 1 Engine and cooling system Engine and cooling system............................................................................................................................. 2 Radiator, power train, oil cooler............................................................................................................ 2 Engine control ...................................................................................................................................... 4
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- 24. SEN01135-00 10 Structure, function and maintenance standard 2 D68ESS-12 Engine and cooling system 1 Radiator, power train, oil cooler 1 Outline q A reservoir tank has been installed for the radi- ator to make it possible to check the radiator coolant level. q The power train oil cooler is built into the lower tank. Radiator Power train oil cooler (built into the lower tank) Core type D-6 PTO-LS Fin pitch (mm) 4.0 — Heat dissipation capacity (kcal/h) 88,500 25,900 Heat dissipation area (m2 ) 46.19 1.829
- 25. 10 Structure, function and maintenance standard SEN01135-00 D68ESS-12 3 1. Radiator core assembly 2. Fan guard 3. Inlet hose 4. Reservoir tank 5. Outlet hose 6. Lower tank (with built-in power train oil cooler) 7. Fan 8. Coolant filler cap 9. Drain plug 10. Power train oil cooler 11. Boss 12. Cushion A. Power train oil cooler inlet port B. Power train oil cooler outlet port
- 26. SEN01135-00 10 Structure, function and maintenance standard 4 D68ESS-12 Engine control 1 1. Decelerator pedal 2. Throttle lever 3. Clutch 4. Cable 5. Fuel injection pump Lever positions [1] Low idle [2] High idle Outline q The engine speed is controlled by throttle lever (2) or decelerator pedal (1).