Komatsu D68ESS-12 Bulldozer Service Manual
591 pages · Publication SEN01128-05
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- Models
- D68ESS-12
- Serial coverage
- 1001 and up, J10001 and up
- Manual type
- Service Manual
- Pages
- 591
- Publication
- SEN01128-05
- Condition
- Brand new
What's inside
From the manual's own table of contents: 121 sections, 202 entries. See sample pages (PDF, 682 KB)
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
Specification and technical data
Specification drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
Engine and cooling system
Radiator, power train, oil cooler
Engine control
Power train, Part 1
Power train system
Power train skeleton
Power train unit
Power train hydraulic piping diagram
Show all 121 sections
Damper, universal joint
Torque converter and PTO
Transmission control
Transmission
Transmission control valve
Main relief valve
Lubrication relief valve
Steering and brake control
Power train, Part 2
Bevel gear shaft, steering clutch and brake
Brake valve
Scavenging pump strainer
Power train oil strainer
Power train oil filter
Final drive34 topics
- Undercarriage and frame
- Main frame
- Suspension
- Track frame
- Recoil spring
- Idler
- Track roller
- Carrier roller
- Track shoe
- Hydraulic system, Part 1
- 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
- Hydraulic system, Part 2
- 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 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
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
Starting motor is not cranked when starting switch is turned to ON
Lamps do not light up
Troubleshooting of hydraulic and mechanical system (H-mode)
Table of failure modes and causes (hydraulic, mechanical system)
Brake does not work
Machine does not turn (can travel in a straight line)
Overruns when turning
Can turn in only one direction (when steering lever is operated)
Excessive time lag
Machine can travel in only one direction (forward or reverse)
Machine does not move (when engine is started and lever is shifted to 2nd or 3rd)
Machine does not move in any speed range
Power train oil temperature rises too high
Drawbar pull is weak, travel speed is slow
Abnormal noise is generated from around hydraulic pump
Work equipment speed is slow or lacks power
No work equipment moves
Blade lift or tilt cylinder speed is slow or lacks power
Blade angle cylinder speed is slow or lacks power
Hydraulic drift of blade lift is excessive
Hydraulic drift of blade tilt is excessive
Hydraulic drift of blade angle is excessive47 topics
- Troubleshooting of machine monitor system (M-mode)
- Table of failure modes and causes (machine monitor system)
- Electrical circuit diagrams for each system
- Caution item lights up
- Gauge is abnormal
- Service meter does not move after engine is started
- Monitor panel lighting does not light up (front lamps are normal)
- General information on disassembly and assembly
- How to read this manual
- Coating materials list
- Special tool list
- Sketches of special tools
- 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
- 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
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
Removal and installation of dashboard assembly
Removal and installation of panel assembly
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
Electrical circuit diagram (Serial No. 1003 and up, J10011 and up)
Electrical circuit diagram
Inside this manual
Real pages from this service manual (591 pages). Open the sample pages (PDF, 682 KB)
- Specifications, page 62: 01 Specification
- Diagram, page 269: 40 Troubleshooting
- Troubleshooting, page 350: 40 Troubleshooting
- Foldout diagram, page 589: Trimming dozer
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, 591 pages
Quantity one is the manual described above.
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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.
Other editions and similar models
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).