Komatsu D66S-1 Crawler Loader Shop Manual SEBM0142A10 PDF

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Komatsu D66S-1 Crawler Loader Shop Manual SEBM0142A10 – PDF DOWNLOAD

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Komatsu D66S-1 Crawler Loader Shop Manual SEBM0142A10 – PDF DOWNLOAD 

Language : English
Pages : 626
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D66S-1 Crawler Loader Shop Manual SEBM0142A10 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL No.
D66S-1                          1001 and up

COVER 1
CONTENTS 2
01 GENERAL 35
GENERAL VIEW 36
ASSEMBLY DRAWING 37
SPECIFICATIONS 38
ENGINE ASSEMBLY DRAWING 40
ENGINE SPECIFICATIONS 44
WEIGHT TABLE 45
TABLE OF OIL AND COOLANT QUANTITIES 46
OUTLINE 47
LAYOUT OF LIST ELECTRONIC CONTROL, MONITOR, SENSORS, ACTUATORS AND CONTROLLER 49
MONITORING SYSTEM 50
10 ENGINE 51
11 STRUCTURE AND FUNCTION 51
ENGINE MOUNT 52
RADIATOR AND COOLER 53
FUEL TANK AND PIPING 54
ENGINE CONTROL 55
12 TESTING AND ADJUSTING 56
STANDARD VALUE TABLE 57
TOOL LIST FOR TESTING AND ADJUSTING 58
ADJUSTING VALVE CLEARANCE 59
MEASURING COMPRESSION PRESSURE 60
TESTING AND ADJUSTING FUEL INJECTION TIMING 61
TESTING AND ADJUSTING FAN BELT TENSION 63
MEASURING ENGINE OIL PRESSURE AND TEMPERATURE 64
MEASURING BLOW-BY PRESSURE 65
13 DISASSEMBLY AND ASSEMBLY 66
STARTING MOTOR ASSEMBLY 67
REMOVAL 67
INSTALLATION 67
ALTERNATOR ASSEMBLY 68
REMOVAL 68
INSTALLATION 68
FUEL INJECTION PUMP ASSEMBLY 69
REMOVAL 69
INSTALLATION 69
WATER PUMP ASSEMBLY 70
REMOVAL 70
INSTALLATION 70
NOZZLE HOLDER ASSEMBLY 71
REMOVAL 71
INSTALLATION 71
CYLINDER HEAD ASSEMBLY 72
REMOVAL 72
INSTALLATION 79
TURBOCHARGER ASSEMBLY 88
REMOVAL 88
INSTALLATION 88
AFTER-COOLER CORE ASSEMBLY 89
REMOVAL 89
INSTALLATION 90
RADIATOR ASSEMBLY 91
REMOVAL 91
INSTALLATION 91
ENGINE OIL COOLER ASSEMBLY 93
REMOVAL 93
INSTALLATION 93
ENGINE, RADIATOR ASSEMBLY 94
REMOVAL 94
INSTALLATION 95
ENGINE ASSEMBLY 96
REMOVAL 96
INSTALLATION 96
HOOD ASSEMBLY (SERIAL NO 1001-1399) 97
OPENING 97
CLOSING 97
HOOD ASSEMBLY (SERIAL NO 1400 AND UP) 98
REMOVAL 98
INSTALLATION 98
HST OIL COOLER ASSEMBLY (SERIAL NO 1001-1399) 99
REMOVAL 99
INSTALLATION 99
HST OIL COOLER ASSEMBLY (SERIAL NO 1400 AND UP) 100
REMOVAL 100
INSTALLATION 100
20 POWER TRAIN 101
21 STRUCTURE AND FUNCTION 101
GENERAL 102
POWER TRAIN HYDRAULIC SYSTEM 104
DAMPER 108
DRIVE SHAFT (INPUT, OUTPUT) 110
TORQUE SPLITTER 111
HST (HYDROSTATIC TRANSMISSION) 113
HYDROSTATIC TRANSMISSION PIPING 115
SPEED CONTROL 117
HYDROSTATIC TRANSMISSION OIL CIRCUIT DIAGRAM 118
COMPONENTS OF HST (SERIAL NO 1001-1399) 124
HST PUMP GROUP (SERIAL NO 1001-1399) 125
COMPONENTS OF HST (SERIAL NO 1400 AND UP) 128
HST PUMP GROUP (SERIAL NO 1400 AND UP) 129
HST MOTOR GROUP 158
HST CHARGING PUMP AND HST SERVO PUMP 165
HST FILTER 168
CHARGE OIL FILTER BYPASS VALVE AND CHARGE OIL SAFETY VALVE 169
HST TANK 172
STEERING CONTROL 173
BRAKE CONTROL 174
BRAKE AND BRAKE CONTROL VALVE 175
FINAL DRIVE 184
22 TESTING AND ADJUSTING 186
STANDARD VALUE TABLE 187
TESTING AND ADJUSTING 189
BLEEDING AIR FROM HST BRAKE CIRCUIT 189
TESTING AND ADJUSTING HYDRAULIC PRESSURE 190
MEASURING OIL TEMPERATURE 192
MEASURING OPERATING FORCE 193
MEASURING AND ADJUSTING TRAVEL 194
PROCEDURE FOR ADJUSTMENT OF TRAVEL DEVIATION 199
TROUBLESHOOTING 205
1 OUTLINE OF TROUBLESHOOTING FOR HST AND HST ELECTRONIC CONTROL SYSTEM 206
2 HST TROUBLESHOOTING 209
CONTENTS 209
1 INTRODUCTION 210
2 ASSUMPTIONS WHEN TROUBLESHOOTING 210
3 PRECAUTIONS REGARDING DIRT AND CONTAMINATION IN OIL 210
4 TROUBLESHOOTING TOOLS AND REPLACEMENT PARTS FOR TROUBLESHOOTING 210
5 PRECAUTIONS FOR UNIT EXCHANGE 211
6 TROUBLESHOOTING 212
H-1 MACHINE DOES NOT MOVE FORWARD OR IN REVERSE 212
H-2 MACHINE MOVES IN ONE DIRECTION (FORWARD OR REVERSE) BUT NOT IN OTHER DIRECTION 214
H-3 MACHINE MOVES EVEN WHEN SPEED CONTROL LEVER IS IN NEUTRAL 215
H-4 MACHINE DEVIATES GRADUALLY 215
H-5 MACHINE DEVIATES SHARPLY 218
H-6 TRACKS COUNTERROTATE 221
H-7 MACHINE MOVES IN OPPOSITE DIRECTION 221
H-7′ WHEN STARTING ON LEVEL GROUND 222
H-8 MACHINE MOVES SUDDENLY WHEN STARTING 222
H-9 WHEN MACHINE STARTS, FRONT OF MACHINE WAVERS SLIGHTLY 223
H-10 EXCESSIVE TIME LAG WHEN STARTING 224
H-11 POOR ACCELERATION 224
H-12 DIFFICULT TO TURN 225
H-13 MACHINE TURNS SHARPLY INSTEAD OF GRADUALLY 226
H-14 MACHINE TURNS IN OPPOSITE DIRECTION 226
H-15 MACHINE DOES NOT RETURN TO STRAIGHT LINE 226
H-16 MACHINE OVERSTEERS 227
H-17 MACHINE DOES NOT SLOW DOWN SMOOTHLY 228
H-18 MACHINE DEVIATES WHEN SLOWING DOWN 229
H-19 MACHINE CANNOT BE CONTROLLED ON DOWNHILL SLOPES 230
H-20 MACHINE STOPS SUDDENLY 230
H-21 MACHINE LACKS POWER (MACHINE CANNOT TRAVEL AT MAXIMUM SPEED ) 231
H-22 MACHINE LACKS POWER (ENGINE STALLS ) 232
H-23 EXCESSIVE NOISE FROM HST 233
H-24 HST OIL TEMPERATURE RISES TOO HIGH 234
23 DISASSEMBLY AND ASSEMBLY 235
DAMPER ASSEMBLY 236
REMOVAL 236
INSTALLATION 237
TORQUE SPLITTER ASSEMBLY 238
REMOVAL 238
INSTALLATION 241
DISASSEMBLY 244
ASSEMBLY 247
HST ASSEMBLY 250
REMOVAL 250
INSTALLATION 254
HST UNIT 260
DISASSEMBLY 260
ASSEMBLY 277
HST PUMP SERVO VALVE ASSEMBLY 332
REMOVAL 332
INSTALLATION 332
ASSIST VALVE ASSEMBLY 333
REMOVAL 333
INSTALLATION 334
DISASSEMBLY 335
ASSEMBLY 337
NEUTRAL BYPASS VALVE ASSEMBLY 339
DISASSEMBLY 339
ASSEMBLY 339
HST MOTOR SERVO VALVE ASSEMBLY 340
REMOVAL 340
INSTALLATION 340
CHARGING, SERVO PUMP ASSEMBLY 341
REMOVAL 341
INSTALLATION 341
CHARGE FILTER BYPASS VALVE ASSEMBLY 342
REMOVAL 342
INSTALLATION 342
DISASSEMBLY 343
ASSEMBLY 343
BRAKE CONTROL VALVE ASSEMBLY 344
REMOVAL 344
INSTALLATION 345
DISASSEMBLY 346
ASSEMBLY 348
FINAL DRIVE ASSEMBLY 351
REMOVAL 351
INSTALLATION 353
DISASSEMBLY 355
ASSEMBLY 366
24 MAINTENANCE STANDARD 374
DAMPER 375
TORQUE SPLITTER 376
CHARGING PUMP AND SERVO PUMP 377
BYPASS VALVE FOR CHARGING FILTER 378
BRAKE 379
FINAL DRIVE 380
30 UNDERCARRIAGE 382
31 STRUCTURE AND FUNCTION 382
TRACK GROUP 383
RECOIL SPRING 384
IDLER 385
CARRIER ROLLER 386
TRACK ROLLER 387
TRACK 388
SUSPENSION 389
33 DISASSEMBLY AND ASSEMBLY 391
TRACK FRAME ASSEMBLY 392
REMOVAL 392
INSTALLATION 393
RECOIL SPRING ASSEMBLY 394
REMOVAL 394
INSTALLATION 395
DISASSEMBLY 396
ASSEMBLY 397
IDLER ASSEMBLY 398
REMOVAL 398
INSTALLATION 398
TRACK ROLLER ASSEMBLY 399
REMOVAL 399
INSTALLATION 399
CARRIER ROLLER ASSEMBLY 400
REMOVAL 400
INSTALLATION 400
TRACK SHOE ASSEMBLY 401
REMOVAL 401
INSTALLATION 403
ADJUSTING TENSION 405
PIVOT SHAFT ASSEMBLY 406
REMOVAL 406
INSTALLATION 407
34 MAINTENANCE STANDARD 408
TRACK FRAME 409
RECOIL SPRING 410
IDLER 411
TRACK ROLLER 413
CARRIER ROLLER 415
MEASURING PROCEDURE OF ROLLERS 416
TRACK SHOE 418
MEASURING PROCEDURE OF TRACK 420
SUSPENSION 422
60 HYDRAULIC SYSTEM 424
61 STRUCTURE AND FUNCTION 424
GENERAL 425
HYDRAULIC CIRCUIT SYSTEM 427
HYDRAULIC CONTROL 429
HYDRAULIC AND UNLOADER PUMPS 430
BUCKET CONTROL VALVE 431
UNLOADER VALVE 436
HYDRAULIC TANK 439
HYDRAULIC CYLINDER 440
62 TESTING AND ADJUSTING 441
STANDARD VALUE TABLE 442
TESTING AND ADJUSTING HYDRAULIC PRESSURE 443
MEASURING HYDRAULIC OIL TEMPERATURE 444
TESTING AND ADJUSTING TRAVEL AND OPERATING FORCE OF CONTROL LEVER 444
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT 445
ADJUSTING ELECTRIC POSITIONER 446
63 DISASSEMBLY AND ASSEMBLY 447
MAIN CONTROL VALVE, PLATE ASSEMBLY (SERIAL NO 1001-1399) 448
REMOVAL 448
INSTALLATION 449
MAIN CONTROL VALVE, PLATE ASSEMBLY (SERIAL NO 1400 AND UP) 450
REMOVAL 450
INSTALLATION 451
MAIN CONTROL VALVE ASSEMBLY 452
REMOVAL 452
INSTALLATION 454
RIPPER CONTROL VALVE ASSEMBLY 455
REMOVAL 455
INSTALLATION 455
MAIN CONTROL VALVE ASSEMBLY 456
DISASSEMBLY 456
ASSEMBLY 458
UNLOADER VALVE ASSEMBLY 460
REMOVAL 460
INSTALLATION 460
DISASSEMBLY 462
ASSEMBLY 463
HYDRAULIC PUMP, UNLOADER PUMP ASSEMBLY 464
REMOVAL 464
INSTALLATION 464
DUMP CYLINDER ASSEMBLY 465
REMOVAL 465
INSTALLATION 465
LIFT CYLINDER ASSEMBLY 466
REMOVAL 466
INSTALLATION 467
HYDRAULIC CYLINDER ASSEMBLY 468
DISASSEMBLY 468
ASSEMBLY 470
64 MAINTENANCE STANDARD 473
HYDRAULIC CONTROL VALVE 474
UNLOADER VALVE 476
HYDRAULIC AND UNLOADER PUMPS 478
DUMP CYLINDER 479
LIFT CYLINDER 480
70 WORK EQUIPMENT 481
71 STRUCTURE AND FUNCTION 481
BUCKET LINK 482
BUCKET CONTROL 484
BUCKET 486
73 DISASSEMBLY AND ASSEMBLY 487
WORK EQUIPMENT ASSEMBLY 488
REMOVAL 488
INSTALLATION 489
74 MAINTENANCE STANDARD 490
BUCKET LINK 491
BUCKET 493
80 ELECTRIC AND ELECTRONIC SYSTEM 494
81 STRUCTURE AND FUNCTION 494
OUTLINE OF ELECTRIC AND ELECTRONIC SYSTEMS 495
HST CONTROL SYSTEM 497
SELF-CHECK FUNCTION OF HST CONTROL SYSTEM 501
HST CONTROLLER 502
POTENTIOMETER 503
ENGINE SPEED SENSOR 504
ELECTRONIC MONITORING SYSTEM 506
WIRING DIAGRAM FOR CAB 519
ELECTRIC CIRCUIT 520
82 TESTING AND ADJUSTING 521
OUTLINE OF TROUBLESHOOTING 522
WAY OF USING TROUBLESHOOTING TABLES 523
PRECAUTIONS WHEN TROUBLESHOOTING 524
ELECTRICAL AND ELECTRONIC EQUIPMENT FOR D66S-1 527
TROUBLESHOOTING FOR MONITOR PANEL 534
1 CHECK THE FOLLOWS BEFORE STARTING TROUBLESHOOTING 534
2 WIRING DIAGRAM AS TO MONITOR PANEL 535
3 CONNECTOR NUMBERS FOR MONITOR PANEL 536
4 METHOD OF REMOVING MONITOR PANEL BOX 539
5 TROUBLESHOOTING CHART FOR MONITOR PANEL 540
6 TROUBLESHOOTING 541
TROUBLESHOOTING OF HST ELECTRONIC CONTROL SYSTEM 566
1 OUTLINE 566
2 SELF-CHECK FUNCTION BY MONITOR PANEL 569
3 TROUBLESHOOTING OF HST ELECTRONIC CONTROL SYSTEM BY USING ATESTER 573
CONTENTS 573
1 TROUBLESHOOTING TOOLS 574
2 TROUBLESHOOTING 576
A IN CASE THAT SELF-CHECK FUNCTION ON THE MONITOR PANEL (“HST ELECTRONIC SYSTEM MONITOR 1″,”HST ELECTRONIC SYSTEM MONITOR 2″,”HST OIL PRESSURE MONITOR”,”WARNING LAMP”,”ALARM BUZZER”) IS DISPLAYED 576
T-1 DROP IN HST CHANGE PRESSURE 576
T-2 NO SUPPLY OF ELECTRIC POWER TO HST CONTROLLER 578
T-3 BREAKDOWN IN SPEED CONTROL LEVER SYSTEM 581
T-4 BREAKDOWN IN PEDAL SYSTEM 587
T-5 BREAKDOWN IN HST SERVO SYSTEM (SOLENOID VALVE) 589
T-6 BREAKDOWN IN THE FUEL CONTROL LEVER AND ENGINE SPEED SENSOR 591
T-7 BREAKDOWN IN STRAIGHT TRAVEL COMPENSATION SYSTEM 595
B IN CASE THAT DISPLAY OF MONITOR PANEL IS NORMAL, BUT MACHINE MOVEMENT IS ABNORMAL 597
T-8 MACHINE DOES NOT MOVE EITHER FORWARD OR IN REVERSE 597
T-9 EITHER FORWARD OR REVERSE WORKS 601
T-10 MACHINE STOPS WHEN TRAVELING WITH NO LOAD 604
T-11 MACHINE TRAVELS STRAIGHT, BUT THERE IS A PROBLEM WITH MACHINE SPEED 607
T-12 WHILE TRAVELING, ONE SIDE STOPS MOVING 608
T-13 WHILE TRAVELING, ONE SIDE IS SLOWER OR FASTER THAN THE OTHER (MACHINE DEVIATES) 610
HOW TO INSTALL THE POTENTIOMETER 611
83 DISASSEMBLY AND ASSEMBLY 613
ELECTRONIC CONTROLLER ASSEMBLY, MONITOR ASSEMBLY 614
REMOVAL 614
INSTALLATION 616
90 OTHERS 618
91 STRUCTURE AND FUNCTION 618
ROPS CAB 619
AIR CONDITIONER ASSEMBLY 620
AIR CONDITIONER PIPING 621
93 DISASSEMBLY AND ASSEMBLY 622
OPERATOR’S CAB, FRAME ASSEMBLY (SERIAL NO 1001-1399) 623
REMOVAL 623
INSTALLATION 624
OPERATOR’S CAB, FRAME ASSEMBLY (SERIAL NO 1400 AND UP) 625
REMOVAL 625
INSTALLATION 626

DESCRIPTION:

Komatsu D66S-1 Crawler Loader Shop Manual SEBM0142A10 – PDF DOWNLOAD 

MACHINE MODEL       SERIAL No.
D66S-1                          1001 and up

GENERAL PRECAUTIONS :

Mistakes in operation are extremely dangerous. Read the OPERATION & MAINTENANCE MANUAL carefully BEFORE operating the machine.

PREPARATIONS FOR WORK:

S.V 28/12/24