Komatsu D63E-12 Bulldozer Service Manual

Name: Komatsu D63E-12 Bulldozer Service Manual
Brand: MidWestTech
SKU: SEN04151-00
Price: 69.87 USD
Availability: InStock

677 pages · Publication SEN04151-00

$69.87

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Models: D63E-12
Serial coverage: 2001 and up
Manual type: Service Manual
Pages: 677
Publication: SEN04151-00
Condition: Brand new

Komatsu D63E-12 Bulldozer Service Manual, publication SEN04151-00

What's inside

From the manual's own table of contents: 8 sections, 267 entries. See sample pages (PDF, 665 KB)

Search the contents

Index and foreword49 topics

Shop Manual, contents binder, binder label and tabs
Index and foreword
Index
Foreword and general information
Specification
Structure, function and maintenance standard
Engine and cooling system
Power train, Part 1
Power train, Part 2
Undercarriage and frame
Hydraulic system, Part 1
Hydraulic system, Part 2
Work equipment
Cab and its attachments
Electrical system
Standard value table
Standard service value table
Testing and adjusting
Testing and adjusting, Part 1
Testing and adjusting, Part 2
Troubleshooting
General information on troubleshooting
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
Engine and cooling system
Power train, Part 1
Power train, Part 2
Undercarriage and frame
Hydraulic system
Work equipment
Cab and its attachments
Diagrams and drawings
Hydraulic diagrams and drawings
Electrical diagrams and drawings
Composition of shop manual
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

Specification5 topics

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

Structure, function and maintenance standard47 topics

Radiator, power train, oil cooler
Engine control
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
Main frame
Suspension
Track frame
Recoil spring
Idler
Track roller
Carrier roller
Track shoe
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 mount
ROPS guard
Machine monitor system
Monitor panel
Sensors

Standard value table3 topics

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

Testing and adjusting25 topics

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

Troubleshooting60 topics

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
Installing positions of fuses
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
E-3 Automatic preheating is not carried out when glow switch is turned to Auto
E-4 Wiper does not work
E-5 No washer fluid is sprayed out
E-6 Air conditioner has no effect
E-7 Engine does not start (Engine stop solenoid malfunctions)
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 Machine overruns when turning
H-4 Machine 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 All work equipment speed is slow or lacks power
H-13 No work equipment moves
H-14 Hydraulic drift of blade lift is excessive
H-15 Hydraulic drift of blade tilt is excessive
Method of using troubleshooting charts
S-1 Starting performance is poor (Starting always takes time)
S-2 Engine does not start
S-3 Engine does not pick up smoothly (Follow-up is poor)
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly (Hunting)
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (Incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant, or coolant spurts back, or coolant level goes down
S-12 Oil pressure monitor lights up (Drop in oil pressure)
S-13 Oil level rises (Coolant, fuel in oil)
S-14 Coolant temperature becomes too high (Overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
Table of failure modes and causes (Machine monitor system)
Forestry specification, general construction specification
M-1. No display is given on monitor panel when starting switch is turned to ON
M-2. When starting switch is turned to ON, all monitor panel lamps light up and do not go out
M-3. Preheating is abnormal
M-4. CAUTION items light up or flash
M-5. Buzzer is abnormal
M-6. Warning lamp is abnormal
M-7. Gauge is abnormal
M-8. Service meter does not move after engine is started
M-9. Monitor panel lighting does not light up (head lamps are normal)

Disassembly and assembly65 topics

How to read this manual
Coating materials list
Special tool list
Sketches of special tools
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
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
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
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
Removal and installation of blade assembly
Removal and installation of ripper assembly
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 drawings5 topics

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

Inside this manual

Real pages from this service manual (677 pages). Open the sample pages (PDF, 664 KB)

Sample pages from the Komatsu D63E-12 Bulldozer Service Manual: Specifications, Troubleshooting, Diagram, Foldout diagram

Specifications, page 60: Weight table
Troubleshooting, page 270: 100 General information on troubleshooting
Diagram, page 640: 700 Cab and its attachments
Foldout diagram, page 673: Electrical circuit diagram

This is a service manual

Here's how it compares to the other manual types.

This manual

Service manual

Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.

Operator's manual

Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.

What it's used for

Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.

Service shops and owner/operators who repair their own equipment

Identifying correct parts and seeing how assemblies come apart and go back together

Keeping equipment running with less downtime

Factory manual, 677 pages

Quantity one is the manual described above.

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60-day returns

Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy

Binder not included

Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.

Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).