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Komatsu d65 px 15e0 dozer bulldozer service repair manual sn 69001 and up

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This document provides specifications and maintenance information for Bulldozer models D65EX, D65PX, and D65WX-15E0. It includes sections on specifications, structure and function, maintenance standards, testing and adjusting procedures, and troubleshooting. Serial numbers for the models start at 69001. The document contains diagrams, specifications, technical data, and instructions for servicing and repairing components of the bulldozers.

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BULLDOZER SEN00046-09 D65EX -15E0 D65PX -15E0 D65WX-15E0 SERIAL NUMBERS D65EX- 69001 D65PX- 69001 D65WX-69001 and up
SEN00055-09 00 Index and foreword 4 D65EX, PX, WX-15E0 Table of contents 1 00 Index and foreword Index ............................................................................................................................... SEN00055-09 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information.................................................................................. SEN00056-04 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...................................................................................... SEN00057-04 Specification dimensions ......................................................................................................... 2 Specifications........................................................................................................................... 3 Weight table............................................................................................................................. 8 Table of fuel, coolant and lubricants ........................................................................................ 10 10 Structure, function and maintenance standard Engine and cooling system............................................................................................. SEN00281-01 Cooling system ........................................................................................................................ 2 Cooling fan pump..................................................................................................................... 4 Cooling fan motor .................................................................................................................... 12 Power train, Part 1 .......................................................................................................... SEN00282-02 Power train............................................................................................................................... 2 HSS system............................................................................................................................. 4 General view of power train unit .............................................................................................. 6 Power train hydraulic piping drawing....................................................................................... 8 Transmission, steering and brake control................................................................................ 10 Damper and universal joint...................................................................................................... 12 Torque converter and PTO ...................................................................................................... 15 Transmission............................................................................................................................ 20 Transmission clutch ECMV...................................................................................................... 36 Main relief valve and torque converter relief valve .................................................................. 42 Lubrication relief valve............................................................................................................. 44 Power train, Part 2 .......................................................................................................... SEN00283-03 Bevel gear shaft, HSS and brake ............................................................................................ 2 Brake valve.............................................................................................................................. 24 Final drive ................................................................................................................................ 30 Undercarriage and frame................................................................................................ SEN00284-04 Main frame............................................................................................................................... 2 Suspension.............................................................................................................................. 4 Track frame and idler cushion.................................................................................................. 10 Idler.......................................................................................................................................... 14 Track roller............................................................................................................................... 16 Carrier roller............................................................................................................................. 20 Sprocket................................................................................................................................... 22 Track shoe ............................................................................................................................... 26
00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 5 Hydraulic system, Part 1................................................................................................. SEN00285-01 Work equipment hydraulic piping diagram .............................................................................. 2 Work equipment control........................................................................................................... 4 Hydraulic tank and filter ........................................................................................................... 6 Scavenging pump.................................................................................................................... 8 Power train and steering lubrication pump .............................................................................. 9 HSS pump ............................................................................................................................... 10 HSS motor............................................................................................................................... 28 Hydraulic system, Part 2................................................................................................. SEN00286-01 Control valve............................................................................................................................ 2 Self pressure reducing valve ................................................................................................... 36 Hydraulic system, Part 3................................................................................................. SEN00287-01 PPC valve (blade lift, blade tilt)................................................................................................ 2 PPC valve (ripper) ................................................................................................................... 8 Electric lever (steering)............................................................................................................ 12 Quick drop valve...................................................................................................................... 16 PPC lock valve ........................................................................................................................ 18 Accumulator............................................................................................................................. 19 Work equipment.............................................................................................................. SEN00288-00 Blade ....................................................................................................................................... 2 Cutting edge and end bit ......................................................................................................... 6 Ripper...................................................................................................................................... 7 Hydraulic cylinder .................................................................................................................... 8 Piston valve ............................................................................................................................. 11 Cab and its attachments ................................................................................................. SEN00289-00 Cab mount............................................................................................................................... 2 Cab.......................................................................................................................................... 3 Air conditioner.......................................................................................................................... 5 Electrical system............................................................................................................. SEN00290-03 Monitor system ........................................................................................................................ 2 Monitor panel........................................................................................................................... 4 Engine control.......................................................................................................................... 13 Engine control system ............................................................................................................. 14 Cooling system control system................................................................................................ 16 System components ................................................................................................................ 18 Palm command control system ............................................................................................... 26 KOMTRAX system .................................................................................................................. 28 Sensor ..................................................................................................................................... 30 Standard service value table Standard service value table........................................................................................... SEN00584-02 Standard service value table for engine .................................................................................. 2 Standard service value table for chassis ................................................................................. 4 30 Testing and adjusting Testing and adjusting, Part 1 .......................................................................................... SEN00585-03 Tools for testing, adjusting, and troubleshooting ..................................................................... 3 Measuring engine speed ......................................................................................................... 6 Measuring intake air pressure (boost pressure) ...................................................................... 8 Measuring exhaust temperature.............................................................................................. 10 Measuring exhaust gas color................................................................................................... 12 Adjusting valve clearance........................................................................................................ 13 Measuring compression pressure ........................................................................................... 16 Measuring blow-by pressure ................................................................................................... 20 Measuring engine oil pressure ................................................................................................ 21 Handling of fuel system devices.............................................................................................. 22 Releasing residual pressure from fuel system......................................................................... 22
SEN00055-09 00 Index and foreword 6 D65EX, PX, WX-15E0 Testing fuel pressure................................................................................................................ 23 Testing fuel return and leak amount......................................................................................... 28 Bleeding air from fuel circuit .................................................................................................... 30 Testing fuel circuit for leakage ................................................................................................. 31 Handling of reduced cylinder mode operation ......................................................................... 32 Testing and adjusting air conditioner compressor belt tension ................................................ 33 Adjusting fuel control dial and decelerator pedal..................................................................... 34 Measuring power train oil pressure.......................................................................................... 36 Adjusting transmission speed sensor (replacement procedure).............................................. 40 Simple method to test brake performance............................................................................... 41 Adjusting brake pedal .............................................................................................................. 42 Adjusting parking brake lever .................................................................................................. 44 Emergency escape method when power train has trouble...................................................... 45 Adjusting clearance of idler...................................................................................................... 48 Inspecting wear of sprocket..................................................................................................... 49 Testing and adjusting track shoe tension................................................................................. 49 Testing and adjusting work equipment and HSS oil pressure.................................................. 50 Testing control circuit basic pressure....................................................................................... 53 Measuring PPC valve output pressure .................................................................................... 54 Adjusting work equipment PPC valve play .............................................................................. 56 Measuring internal leakage of work equipment cylinder.......................................................... 58 Bleeding air from work equipment cylinder.............................................................................. 58 Releasing residual pressure in work equipment cylinder......................................................... 59 Checking parts which caused hydraulic drift of blade or ripper................................................ 60 Adjusting work equipment lock lever ....................................................................................... 61 Measuring fan motor speed..................................................................................................... 62 Measuring fan pump circuit pressure....................................................................................... 63 Bleeding air from fan pump...................................................................................................... 64 Adjusting straight tiltdozer........................................................................................................ 65 Testing and adjusting operator cab.......................................................................................... 67 Testing and adjusting, Part 2........................................................................................... SEN00586-01 Special functions of monitor panel (EMMS)............................................................................. 2 Testing and adjusting, Part 3........................................................................................... SEN00587-02 Handling of voltage circuit of engine controller ........................................................................ 2 Adjustment method when controller has been replaced.......................................................... 2 Preparation work for troubleshooting for electric system......................................................... 4 Inspection procedure of diode ................................................................................................. 9 Pm-Clinic service..................................................................................................................... 10 How to start operation of KOMTRAX terminal ......................................................................... 20 Lamp display of KOMTRAX terminal....................................................................................... 24 40 Troubleshooting General information on troubleshooting.......................................................................... SEN00588-04 Points to remember when troubleshooting .............................................................................. 2 How to proceed troubleshooting.............................................................................................. 3 Checks before troubleshooting................................................................................................ 4 Classification and procedures of troubleshooting.................................................................... 5 How to distinguish wire code ................................................................................................... 8 Connection table for connector pin numbers ........................................................................... 12 T- branch box and T- branch adapter table.............................................................................. 48 Troubleshooting by failure code (Display of code), Part 1 .............................................. SEN00589-03 Failure code table .................................................................................................................... 3 Before troubleshooting by failure codes .................................................................................. 10 Contents of troubleshooting table ............................................................................................ 12 Failure code [1500L0] Transmission clutch: Dual engagement............................................... 14 Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF ....... 16 Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON....... 18
00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 7 Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF....... 20 Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON ...... 22 Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF ............... 24 Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON............... 25 Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF .............. 26 Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON.............. 28 Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF............... 30 Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON .............. 32 Failure code [AB00MA] Alternator: Malfunction....................................................................... 34 Failure code [B@BAZG] Engine oil: Oil pressure too low ....................................................... 34 Failure code [B@BCNS] Radiator coolant: Overheat.............................................................. 35 Failure code [B@CENS] Power train oil: Overheat ................................................................. 35 Failure code [B@HANS] Hydraulic oil: Overheat .................................................................... 36 Failure code [CA111] Engine controller: Abnormality in controller........................................... 37 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal ................................................................. 37 Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected............................................................ 38 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected .... 40 Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected............................................................ 42 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected... 44 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected............................................................ 46 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected ............................................................. 48 Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected............................................................ 50 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected ............................................................. 52 Failure code [CA155] Charge temperature too high and engine speed derated: Exceeded upper control limit of temperature............................................ 54 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected...... 56 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected............................................................ 58 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected ............................................................. 60 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected ... 62 Failure code [CA234] Engine over speed: Excessively high speed ........................................ 64 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected ............................................................. 65 Failure code [CA271] IMV/PCV1 short circuit: Short circuit..................................................... 66 Failure code [CA272] IMV/PCV1 disconnection: Disconnection ............................................. 68 Failure code [CA281] Abnormal supply pump pressure balance: Abnormal pressure feed of fuel ................................................................ 70 Troubleshooting by failure code (Display of code), Part 2 .............................................. SEN00590-04 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit ....................................................................... 4 Failure code [CA323] Injector No. 5 system disconnection or short circuit: disconnection, short circuit ....................................................................... 6 Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit ....................................................................... 8 Failure code [CA325] Injector No. 6 system disconnection or short circuit: disconnection, short circuit ....................................................................... 10 Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit ....................................................................... 12 Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit ....................................................................... 14
SEN00055-09 00 Index and foreword 8 D65EX, PX, WX-15E0 Failure code [CA342] Engine controller data matching error: matching error.......................... 16 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected ...... 18 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected ... 20 Failure code [CA428] Water detection sensor too high: Excessively high voltage detected ... 22 Failure code [CA429] Water detection sensor too low: Excessively low voltage detected ...... 24 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.............. 26 Failure code [CA441] Power source voltage too low: Excessively low voltage detected......... 28 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit .................................. 30 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred ............................................. 32 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected............................................................ 36 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected ............................................................. 38 Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature............................................ 40 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected ......................................................... 41 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected ................................................................ 42 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal........................... 44 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase............ 46 Failure code [CA757] Loss of all engine controller data: Loss of all data ................................ 48 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal.............. 50 Failure code [CA1633] Abnormal KOMNET: Abnormal communication.................................. 52 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected............................................................ 54 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected ............................................................. 55 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected ................................................................ 56 Failure code [CA2265] Electric lift pump disconnection: Disconnection .................................. 58 Failure code [CA2266] Electric lift pump short circuit: Short circuit ......................................... 60 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance .................................... 62 Failure code [CA2555] Air intake heater relay disconnection: Disconnection ......................... 64 Failure code [CA2556] Air intake heater relay short circuit: Short circuit................................. 66 Troubleshooting by failure code (Display of code), Part 3 .............................................. SEN00591-01 Failure code [D110KA] Battery relay: Short circuit................................................................... 4 Failure code [D110KB] Battery relay: Disconnection ............................................................... 6 Failure code [D130KA] Neutral safety relay: Disconnection.................................................... 8 Failure code [D130KB] Neutral safety relay: Short circuit........................................................ 10 Failure code [D161KA] Back-up alarm relay: Disconnection................................................... 12 Failure code [D161KB] Back-up alarm relay: Short circuit....................................................... 14 Failure code [DAFRKR] Monitor panel CAN communication: Defective communication ........ 16 Failure code [DAQ0KT] [DB30KT] Steering and transmission controller: Abnormality in controller ........................................................................... 18 Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller: Power source voltage drop and input ................. 20 Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller: Power source voltage drop and input ................. 22 Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input................................ 24 Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input................................ 26 Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection: Inconsistency in model select signal......................................................... 28
00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 9 Failure code [DB2RKR] Steering and transmission controller CAN communication: Defective communication ......................................................................... 30 Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormality in controller ........................................................................... 32 Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller: Power source voltage drop and input ................. 32 Failure code [DAB32KK] [DAQ2KK] Load power source of steering and transmission controller: Power source voltage drop and input ................. 32 Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input................................ 32 Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input................................ 32 Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model selection: Inconsistency in model select signal ........................................................ 32 Failure code [DD12KA] Shift up switch: Disconnection ........................................................... 34 Failure code [DD12KB] Shift up switch: Short circuit............................................................... 36 Failure code [DD13KA] Shift down switch: Disconnection ...................................................... 38 Failure code [DD13KB] Shift down switch: Short circuit .......................................................... 40 Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection ...................... 42 Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit .......................... 44 Failure code [DDN7KA] Pitch control switch: Disconnection................................................... 46 Failure code [DDN7KB] Pitch control switch: Short circuit ...................................................... 48 Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection ...................... 50 Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit .......................... 50 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range ........................................................... 52 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection........................... 54 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ........................................................... 55 Failure code [DK10KA] Fuel dial: Disconnection..................................................................... 56 Failure code [DK10KB] Fuel dial: Short circuit ........................................................................ 58 Failure code [DK30KA] Steering potentiometer (1): Disconnection......................................... 60 Failure code [DK30KB] Steering potentiometer (1): Short circuit ............................................ 62 Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range............... 64 Failure code [DK30KZ] Steering potentiometer: | Disconnection or short circuit (Double failure).......................................... 65 Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal ............................ 65 Failure code [DK31KA] Steering potentiometer (2): Disconnection......................................... 66 Failure code [DK31KB] Steering potentiometer (2): Short circuit ............................................ 68 Failure code [DK40KA] Brake potentiometer: Disconnection .................................................. 70 Failure code [DK40KB] Brake potentiometer: Short circuit...................................................... 71 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range . 72 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit (Double failure).......................................... 73 Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal ............... 74 Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit ............................... 76 Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection............................ 78 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................ 80 Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit ............................... 82 Troubleshooting by failure code (Display of code), Part 4 .............................................. SEN00592-00 Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit ...................................... 3 Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range 5 Failure code [DLT3KA] Transmission output speed sensor: Disconnection ............................ 6 Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................ 7 Failure code [DV00KB] Alarm buzzer: Short circuit................................................................. 8 Failure code [DW5AKA] Pitch control solenoid: Disconnection............................................... 9 Failure code [DW5AKB] Pitch control solenoid: Short circuit .................................................. 10 Failure code [DW5AKY] Pitch control solenoid: Short circuit to power source line ................. 11
SEN00055-09 00 Index and foreword 10 D65EX, PX, WX-15E0 Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................ 12 Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................... 13 Failure code [DWN1KA] HSS EPC solenoid right: Disconnection........................................... 14 Failure code [DWN1KB] HSS EPC solenoid right: Short circuit .............................................. 15 Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line ............. 16 Failure code [DWN2KA] HSS EPC solenoid left: Disconnection ............................................. 17 Failure code [DWN2KB] HSS EPC solenoid left: Short circuit................................................. 18 Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line ............... 19 Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection .......................................... 20 Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit.............................................. 21 Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line............. 22 Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection .......................................... 23 Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit.............................................. 24 Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line............. 25 Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................................ 26 Failure code [DXH4KB] 1st clutch ECMV: Short circuit ........................................................... 27 Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line.......................... 28 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...................................................... 29 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit.......................................................... 30 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line......................... 31 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ....................................................... 32 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit........................................................... 33 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line.......................... 34 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection............................................... 35 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit................................................... 36 Failure code [DXH7KY] reverse clutch ECMV: Short circuit to power source line................... 37 Failure code [DXH8KA] Forward clutch ECMV: Disconnection ............................................... 38 Failure code [DXH8KB] Forward clutch ECMV: Short circuit................................................... 39 Failure code [DXH8KY] forward clutch ECMV: Short circuit to power source line................... 40 Troubleshooting of electrical system (E-mode)............................................................... SEN00593-02 Contents of troubleshooting table ............................................................................................ 5 E-1 The engine does not start (the starting motor does not turn) ............................................ 6 E-2 The preheater does not operate........................................................................................ 10 E-3 The monitor panel does not light up at all when the starting switch is turned ON............. 14 E-4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out.................................................................................. 15 E-5 While the engine is running, the battery charge level caution lamp flashes...................... 16 E-6 While the engine is running, the emergency warning item flashes. .................................. 18 E-7 While the preheater is operating, the preheating pilot lamp does not light up. ................. 22 E-8 The coolant temperature gauge does not indicate correctly. ............................................ 24 E-9 The power train oil temperature gauge does not indicate correctly................................... 26 E-10 Hydraulic oil temperature gauge does not indicate properly. .......................................... 29 E-11 Fuel gauge does not indicate properly............................................................................. 32 E-12 Gear speed and engine speed are not indicated properly. ............................................. 33 E-13 The preset mode service meter does not indicate normally............................................ 33 E-14 The warning lamp does not flash or does not go out. ..................................................... 33 E-15 The alarm buzzer does not sound or does not stop........................................................ 34 E-16 Auto shift down is not possible or is not released. .......................................................... 36 E-17 The buzzer cancel switch does not work. ....................................................................... 38 E-18 The information switch does not work............................................................................. 40 E-19 The fan cleaning does not operate or cannot be reset.................................................... 42 E-20 The preset mode does not operate or cannot be reset................................................... 44 E-21 The monitor panel cannot be set in the service mode or cannot be set out of the service mode. ..................................................................................... 46 E-22 The back-up alarm does not sound................................................................................. 48 E-23 The head lamp and rear lamp do not light up. ................................................................ 50 E-24 The horn does not sound or does not stop. .................................................................... 53 E-25 Malfunction of wipers ...................................................................................................... 54
00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 11 E-26 Washer does not spray water ......................................................................................... 70 E-27 The air conditioner does not operate .............................................................................. 76 E-28 KOMTRAX system does not operate normally ............................................................... 80 Troubleshooting of hydraulic and mechanical system (H-mode).................................... SEN00594-00 Contents of troubleshooting table............................................................................................ 3 H-1 There is no travel power (no drawbar pull). ...................................................................... 4 H-2 Machine does not move (at 2nd or 3rd speed)................................................................. 5 H-3 Machine does not move at any gear speed...................................................................... 6 H-4 Machine travels only in one direction, forward or in reverse............................................. 7 H-5 When gear is shifted or travel direction is changed, large time lag is made..................... 8 H-6 Machine cannot be steered (Machine does not turn leftward or rightward)...................... 9 H-7 Steering speed or power is low......................................................................................... 9 H- 8 Brake does not work........................................................................................................ 10 H-9 Overheat of power train oil................................................................................................ 11 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor 12 H-11 All work equipment speeds are slow............................................................................... 12 H-12 Work equipment does not move ..................................................................................... 13 H-13 Blade lift speed is slow or lacks power ........................................................................... 13 H-14 Blade tilt speed is slow or lacks power ........................................................................... 14 H-15 Ripper lift speed is slow or lacks power.......................................................................... 14 H-16 Excessive hydraulic drift of blade lift............................................................................... 15 H-17 Excessive hydraulic drift of blade tilt............................................................................... 15 H-18 Excessive hydraulic drift of ripper lift............................................................................... 16 Troubleshooting of engine (S-mode) .............................................................................. SEN00595-01 Method of using troubleshooting charts................................................................................... 3 S-1 Starting performance is poor. ............................................................................................ 6 S-2 Engine does not start ........................................................................................................ 7 S-3 Engine does not pick up smoothly .................................................................................... 10 S-4 Engine stops during operations ........................................................................................ 11 S-5 Engine does not rotate smoothly ...................................................................................... 12 S-6 Engine lacks output (or lacks power) ................................................................................ 13 S-7 Exhaust smoke is black (imcomplete combustion) ........................................................... 14 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 15 S-9 Oil becomes contaminated quickly ................................................................................... 16 S-10 Fuel consumption is excessive ....................................................................................... 17 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)............................. 18 S-12 Oil pressure drops........................................................................................................... 19 S-13 Oil level rises (water, fuel in oil) ...................................................................................... 20 S-14 Coolant temperature becomes too high (overheating).................................................... 21 S-15 Abnormal noise is made ................................................................................................. 22 S-16 Vibration is excessive ..................................................................................................... 23 50 Disassembly and assembly General information on disassembly and assembly ....................................................... SEN00944-04 How to read this manual.......................................................................................................... 2 Coating materials list ............................................................................................................... 4 Special tool list......................................................................................................................... 7 Sketches of special tools......................................................................................................... 13 Engine and cooling system, Part 1 ................................................................................. SEN00945-03 Removal and installation of fuel supply pump assembly ......................................................... 2 Removal and installation of cylinder head assembly............................................................... 6 Removal and installation of fuel injector assembly.................................................................. 21 Removal and installation of engine front oil seal ..................................................................... 23 Removal and installation of engine rear oil seal ...................................................................... 26 Engine and cooling system, Part 2 ................................................................................. SEN00946-03 Removal and installation of engine assembly ......................................................................... 2 Removal and installation of radiator assembly ........................................................................ 9
SEN00055-09 00 Index and foreword 12 D65EX, PX, WX-15E0 Removal and installation of air aftercooler assembly .............................................................. 13 Removal and installation of fan drive assembly....................................................................... 14 Removal and installation of fan motor assembly ..................................................................... 15 Removal and installation of fuel tank assembly....................................................................... 16 Removal and installation of damper assembly ........................................................................ 18 Removal and installation of engine hood assembly................................................................. 19 Power train, Part 1 .......................................................................................................... SEN00947-01 Removal and installation of power train unit assembly............................................................ 2 Disconnection and connection of power train unit assembly................................................... 5 Disassembly and assembly of PTO assembly......................................................................... 9 Disassembly and assembly of torque converter assembly...................................................... 15 Disassembly and assembly of TORQFLOW transmission assembly ...................................... 20 Power train, Part 2 .......................................................................................................... SEN00948-01 Disassembly and assembly of HSS assembly......................................................................... 2 Removal and installation of final drive assembly ..................................................................... 20 Disassembly and assembly of final drive assembly................................................................. 22 Undercarriage and frame, Part 1 .................................................................................... SEN00949-01 Removal and installation of track frame assembly .................................................................. 2 Removal and installation of idler assembly.............................................................................. 4 Disassembly and assembly of idler assembly ......................................................................... 5 Removal and installation of recoil spring assembly ................................................................. 9 Disassembly and assembly of recoil spring assembly............................................................. 10 Removal and installation of track roller assembly.................................................................... 14 Disassembly and assembly of track roller assembly ............................................................... 15 Removal and installation of carrier roller assembly ................................................................. 19 Disassembly and assembly of carrier roller assembly............................................................. 20 Undercarriage and frame, Part 2 .................................................................................... SEN00950-04 Expansion and installation of track shoe assembly (Conventional type track shoe)................ 2 Expansion and installation of track shoe assembly (PLUS type track shoe) ........................... 5 Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)................................................................. 6 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe) .... 19 Field disassembly and assembly of one link (Conventional type track shoe).......................... 32 Field disassembly and assembly of one link (PLUS type track shoe) ..................................... 39 Removal and installation of pivot shaft assembly .................................................................... 44 Removal and installation of equalizer bar assembly................................................................ 45 Disassembly and assembly of equalizer bar side bushing ...................................................... 47 Hydraulic system............................................................................................................. SEN00951-01 Removal and installation of control valve assembly ................................................................ 2 Disassembly and assembly of control valve assembly............................................................ 4 Removal and installation of HSS pump assembly ................................................................... 5 Removal and installation of power train and lubricating oil pump assembly............................ 6 Removal and installation of cooling fan pump assembly ......................................................... 7 Removal and installation of scavenging pump assembly ........................................................ 9 Removal and installation of HSS motor assembly................................................................... 10 Disassembly and assembly of hydraulic cylinder assembly .................................................... 11 Work equipment.............................................................................................................. SEN00952-01 Removal and installation of blade assembly............................................................................ 2 Cab and its attachments ................................................................................................. SEN00953-03 Removal and installation of ROPS guard ................................................................................ 2 Removal and installation of operator’s cab assembly.............................................................. 3 Removal and installation of operator’s cab glass (Stuck glass)............................................... 9 Removal and installation of floor frame assembly ................................................................... 17 Electrical system............................................................................................................. SEN00954-00 Removal and installation of engine controller .......................................................................... 2 Removal and installation of steering and transmission controller assembly............................ 4 Removal and installation of KOMTRAX terminal ..................................................................... 5
00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 13 90 Diagrams and drawings Hydraulic diagrams and drawings................................................................................... SEN00058-01 Power train hydraulic circuit diagram....................................................................................... 2 Hydraulic circuit diagram ......................................................................................................... 3 Electrical diagrams and drawings................................................................................... SEN00059-02 Electrical circuit diagram.......................................................................................................... 3 Connector list and stereogram ................................................................................................ 19
SEN00945-03 50 Disassembly and assembly 2 D65EX, PX, WX-15E0 Engine and cooling system, Part 1 1 Removal and installation of fuel supply pump assembly 1 Special tools Removal k Disconnect the cable from the negative (–) terminal of the battery. a Since the hose band (MIKALOR clamp) cannot be reused, use new one. See [*1]. a The fuel tube connector is new type (To discon- nect it, press its lock from both sides and pull it). See step 22. k The internal parts of the adapters may be damaged when fuel tubes (23), (24) and (25) are removed. Accordingly, replace the adapters with new ones. 1. Close the fuel supply valve from under the fuel tank. 2. Open engine left side cover (1). 3. Remove covers (2) and (3). 4. Remove bracket (4). 5. Disconnect hose (5). [*1] a Make a mark (M) at the tube end of each hose to show the original position of the hose. 6. Loosen adjustment bolt (6) of the air condi- tioner compressor. 7. Loosen the mounting bolt of air conditioner compressor bracket (7). 8. Remove belt (8). [*2] 9. Disconnect air conditioner compressor hose clamp (9). 10. Disconnect wiring harness clamps (10) and (11). 11. Disconnect connector clip (12). 12. Disconnect connector A/C (13). 13. Disconnect ground wire (14). 14. Remove the air conditioner compressor and bracket (7) together. a Do not disconnect the air conditioner com- pressor hose but place it on the track shoe. Symbol Part number Part name Necessity Q’ty N/R Sketch A 1 795-799-1131 Gear t 1 2 795-799-1390 Remover t 1
50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 3 15. Remove high-pressure pipe clamp (15). [*3] 16. Remove right and left bellows (16). [*3] 17. Remove high-pressure pipe (17). [*3] 18. Disconnect lubrication tube (18). [*4] 19. Disconnect clamp (19). 20. Disconnect brackets (20) and (21). [*5] 21. Disconnect connector (22) from the back of bracket (21). 22. Disconnect fuel tube (23). [*6] a While pressing locks (L) at the front and rear of fuel tube (23), pull it down to dis- connect. 23. Disconnect fuel tubes (24) and (25) similarly to fuel tube (23). [*6] 24. Disconnect receiver drier and bracket assem- bly (26). 25. Remove cap (27). 26. Install gear A1 (See the Special tools table) to rotate the crankshaft. a See Testing and adjusting, “Testing and adjusting valve clearance”. 27. Twist off cap (28). a Use a filter wrench etc. to remove the cap. 28. Rotate the crankshaft and set stamp (M) of drive gear (GY) to the top dead center. a Use a mirror. a See Testing and adjusting, “Testing and adjusting valve clearance”. 29. Remove nut (29) and washer (30) from shaft (SH) of the fuel supply pump. a Take care not to drop the nut and washer into the case.
SEN00945-03 50 Disassembly and assembly 4 D65EX, PX, WX-15E0 30. Tighten tool A2 evenly to disconnect shaft (SH) of the fuel supply pump from drive gear (GY). 31. Remove bracket (31). 32. Remove 4 nuts (32) and fuel supply pump assembly (33). Installation q Install the fuel supply pump assembly accord- ing to the following procedure. 1. Install fuel supply pump assembly (33), match- ing projection (P) of its shaft SH to groove (G) of gear (GY). 2. Install bracket (31) to fuel supply pump assem- bly (33) and tighten 4 nuts (32). 2 Mounting nut: Adhesive (LT-2) 3 Mounting nut and bracket mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 3. Set washer (30) and tighten nut (29). a When installing the nut and washer, take care not to drop them into the case. 3 Nut: 178 ± 13 Nm {18.2 ± 1.3 kgm} q Carry out the following installation in the reverse order to removal.
50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 5 [*1] a Use a new MIKALOR clamp. a Set the hose to the original (marked) position. (Insertion depth of air hose: 57 mm) a Set the bridge (BR) so that its clamp bolt will be at the bottom and it will be lapped over band (BD) as follows. Lapped over band dimension (b) : Min. 5 mm 2 Threads of clamp bolt: Lubricating oil: THREEBOND, PAND18B a Do not use an impact wrench. q When reusing the hose a Set the clamp to its original position. 3 MIKALOR clamp: Min. 6 Nm {0.6 kgm} q When using a new hose a Tighten until band gap (BDG) is 5 – 8 mm. [*2] a See Testing and adjusting, “Testing and adjust- ing air conditioner compressor belt tension”. [*3], [*5] q High-pressure pipe, high-pressure pipe clamp and bracket 1) Tighten bracket (21), high-pressure pipe (17), and clamp (15) in order with the fin- gers. 2) Tighten the sleeve nut of high-pressure pipe (17). 3 Sleeve nut: 37.3 ± 4 Nm {3.8 ± 0.4 kgm} 3) Install right and left bellows (16). 4) Tighten clamp (15) and bracket (21) per- manently in order. [*4] 3 Joint bolt of lubrication tube (18): 24 ± 4 Nm {2.45 ± 0.41 kgm} [*5] See [*3]. [*6] q Fuel tubes (23), (24) and (25) k The internal parts of the adapters may be damaged when fuel tubes (23), (24) and (25) are removed. Accordingly, replace the adapters with new ones.
SEN00945-03 50 Disassembly and assembly 6 D65EX, PX, WX-15E0 Removal and installation of cylinder head assembly 1 Special tools Removal k Disconnect the cable from the negative (–) terminal of the battery. a Since the hose band (MIKALOR clamp) cannot be reused, use new one. See [*6]. a The fuel tube connector is new type (To discon- nect it, press its lock from both sides and pull it). See step 21. k The internal parts of the adapters may be damaged when fuel tubes (20) and (61) are removed. Accordingly, replace the adapters with new ones. a The wiring harness connector is new type (To disconnect it, slide the first lock and then press the second lock). See step 26. 1. Remove the engine hood assembly. For details, see “Removal of engine hood assembly”. 2. Drain the coolant. 6 Coolant: Approx. 39 l 3. Remove cover (1). 4. Remove the air hose, tube, and bracket assembly (2). [*1] a If the MIKALOR clamp (MC) is used, do not disconnect the hose. 5. Disconnect dust indicator hose (3). 6. Disconnect air hose (4). [*2] 7. Remove band (5). [*3] 8. Remove air cleaner assembly (6). 9. Remove plate (7). 10. Remove the mounting bolts and lift off muffler assembly (8). 4 Muffler assembly: 25 kg 11. Remove bracket (9). Symbol Part number Part name Necessity Q’ty N/R Sketch A 1 795-799-1131 Gear t 1 3 795-799-6700 Puller t 1 4 795-799-8150 Remover q 1 8 790-331-1120 Wrench (angle) q 1
50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 7 12. Disconnect wiring harness clamp (10). 13. Disconnect terminal HT/A (11) (black). a If the terminal cover is removed from the wiring harness, the label comes off. Accordingly, tape the label. 14. Disconnect terminals (12) (green) and (13) (black and thick). 15. Disconnect connector mounting bolt (14). 16. Disconnect ground terminal (15) (black). a If the terminal cover is removed from the wiring harness, the label comes off. Accordingly, tape the label. In particular, if the labels of terminals HT/A (11) and ground terminal (15) come off, you cannot say which is which, since both terminals HT/A (11) and ground terminal (15) are black and coming from the same wiring harness. 17. Disconnect wiring harness clamp (16). 18. Disconnect bracket (17). 19. Disconnect air cleaner bracket (18). 20. Disconnect coolant hose (19). [*4] a Check the connection end. 21. Press both sides of lock (L) of fuel tube (20) to disconnect. [*5] a Check the connection end. 22. Remove filter and bracket assembly (21). 23. Disconnect air hose (22). [*6] a Make marks at the hose end tube to show the original position of the hose (See the figure below). 24. Disconnect bracket (23). 25. Remove heater relay and plate assembly (24).
SEN00945-03 50 Disassembly and assembly 8 D65EX, PX, WX-15E0 26. Disconnect connector (25) according to the fol- lowing procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull it toward this side to disconnect. a If part (A) does not float when lock (L2) is pressed and pulled toward this side, the connector is not disconnected. In this case, while pressing lock (L2), float part (A) with a small flat-head screwdriver and pull lock (L2) toward this side. 27. Remove bracket (26). 28. Disconnect ground wire (27). 29. Remove air intake connector and tube assem- bly (28). 30. Loosen adjustment bolt (29) of the air condi- tioner compressor. 31. Loosen the mounting bolt of air conditioner compressor bracket (30). 32. Remove air conditioner compressor belt (31). [*7] 33. Disconnect air conditioner compressor hose clamp (32). 34. Disconnect wiring harness clamp (33). 35. Disconnect connector clip (34). 36. Disconnect connector A/C (35). 37. Disconnect ground wire (36). 38. Remove air conditioner compressor and bracket (30) together. a Do not disconnect the air conditioner com- pressor hose but place it on the track shoe. 39. Disconnect muffler drain tube clamp (37). 40. Remove bracket (38).
50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 9 q View of whole air intake unit 41. Remove high-pressure pipe clamp (39). [*8] 42. Remove right and left bellows (40). [*8] 43. Remove high-pressure pipe (41). [*8] 44. Disconnect connector (42). 45. Disconnect clamps (43) and (44). 46. Disconnect connector (45). 47. Disconnect bracket (46). [*8] 48. Disconnect fuel supply pump connector (47). 49. Disconnect connectors (48) – (50). 50. Disconnect 12 high-pressure pipe bellows (51). [*8] 51. Remove high-pressure pipes (52) – (57). [*8] 52. Disconnect fuel return tube (58). [*8] 53. Remove common rail (59). [*8] a Do not remove the fuel pressure sensor (PS) except for its replacement. 54. Disconnect clamp (60). 55. Disconnect fuel tube (61). [*9] 56. Remove bracket (62). 57. Disconnect clamp (63). 58. Disconnect radiator hoses (64) and (65). [*10]
SEN00945-03 50 Disassembly and assembly 10 D65EX, PX, WX-15E0 59. Disconnect bracket (66). 60. Remove heat insulation cover (67). 61. Remove heat insulation covers (68) and (69). 62. Disconnect turbocharger lubrication hose (70). [*11] 63. Disconnect turbocharger lubrication tube (71). [*11] 64. Remove brackets (72) – (77). 65. Sling turbocharger and exhaust manifold assembly (78) temporarily. 66. Remove the mounting bolts and lift off turbo- charger and exhaust manifold assembly (78). [*12] 4 Turbocharger and exhaust manifold assembly: 35 kg 67. Disconnect clamp (79) from the rear of the engine. 68. Remove bracket mounting bolt (80). 69. Disconnect receiver drier and bracket assem- bly (81). 70. Remove cap (82). 71. Install gear A1 (See the Special tools table) to rotate the crankshaft. a See Testing and adjusting, “Testing and adjusting valve clearance”.
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 11 72. Twist off cap (83). a Use a filter wrench etc. to remove the cap. 73. Rotate the crankshaft and set stamp (M) of drive gear (GY) to the top dead center. a Use a mirror. a See Testing and adjusting, “Testing and adjusting valve clearance”. 74. Disconnect clamp (84). 75. Disconnect oil hose (85). 76. Remove cover (86). 77. Remove air intake cover (87). [*13] 78. Remove cylinder head cover (88). [*14] a Referring to Testing and adjusting, "Test- ing and adjusting valve clearance", check to see if the No. 1 cylinder is at the top or the No. 6 cylinder is at the top. 79. Disconnect wiring harness (89) from the injec- tor. a Locations of wiring harnesses (*): Reverse connection is also possible. 80. Loosen locknut (90) and then loosen adjust- ment screw (91) 2 – 3 turns. a This work must be performed so that an excessive force will not be applied to the push rod when the rocker arm is installed. 81. Remove mounting bolt (92) and rocker arm and crosshead assembly (93). a Record the position and direction (shapes of holes "a" and "b") of each crosshead. (When reinstall the crosshead, set it in the same direction.) Color of cable Cylinder No. a Yellow (*) 1, 3, 5 b Orange c Red (*) 2, 4, 6 d Brown
SEN00945-03 50 Disassembly and assembly 12 D65EX, PX, WX-15E0 82. Remove retainer (95) and inlet connector (96). a Before removing retainer (95), remove all dirt from it and its periphery. a Tool A4 (remove) is set for removal of inlet connector (96). (See Special tools table.) 83. Remove 2 mounting bolts (94) of the injector assembly. 84. Using tool A3, remove injector assembly (97). a Take care that dirt and foreign matter will not enter the mounting part of the fuel injector assembly. 85. Remove push rod (98). 86. Remove spacer (99). 87. Work on the other cylinders similarly. 88. Remove rocker housing assembly (100). 89. Remove the 26 bolts and lift off cylinder head assembly (102). 4 Cylinder head assembly: 85 kg 90. Remove cylinder head gasket (103).
50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 13 Installation q Cylinder head assembly a Check that there is no dirt and foreign matter on the cylinder head mounting surface and in the cylinders. 1. Set cylinder head gasket (103) to the cylinder block. a Match the holes of the cylinder head gas- ket (103) to the holes of the block. 2. Sling cylinder head assembly (102) and set it to the block. a Check that the collet is fitted to the groove of each valve stem by lightly hitting the valve stem with a plastic hammer. a Check that cylinder head gasket (103) is matched to the holes of the block. 3. Before tightening the cylinder head mounting bolts, check the following. 1) Measure stem length "a" of each mounting bolt and check that it is shorter than the using limit. 2) Using limit length of bolt: 162.6 mm a If a bolt is longer than the using limit, do not reuse it but replace it. 2 Apply engine oil (SAE15W-40) to the threads and seats of the mount- ing bolts. 4. Tighten the mounting bolts by 2 – 3 turns with the fingers, and then tighten them according to the following procedure. 1) Tighten the cylinder head mounting bolts in the order shown below. 1] 150 ± 9.8 Nm {15.3 ± 1.0 kgm} 2] Return all bolts 360° 3] 115 ± 4.9 Nm {11.7 ± 0.5 kgm} 4] Check tightening torque of 115 ± 4.9 Nm {11.7 ± 0.5 kgm} 5] 120° ± 5° q Tool A8 (See the Special tools table) is set for angle tightening. q When not using angle tightening tool A8 Make a mark on the cylinder head and each bolt with paint and then tighten the bolt by 120° ± 5°.

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Komatsu d65 px 15e0 dozer bulldozer service repair manual sn 69001 and up

  • 1. BULLDOZER SEN00046-09 D65EX -15E0 D65PX -15E0 D65WX-15E0 SERIAL NUMBERS D65EX- 69001 D65PX- 69001 D65WX-69001 and up
  • 2. SEN00055-09 00 Index and foreword 4 D65EX, PX, WX-15E0 Table of contents 1 00 Index and foreword Index ............................................................................................................................... SEN00055-09 Composition of shop manual ................................................................................................... 2 Table of contents...................................................................................................................... 4 Foreword and general information.................................................................................. SEN00056-04 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...................................................................................... SEN00057-04 Specification dimensions ......................................................................................................... 2 Specifications........................................................................................................................... 3 Weight table............................................................................................................................. 8 Table of fuel, coolant and lubricants ........................................................................................ 10 10 Structure, function and maintenance standard Engine and cooling system............................................................................................. SEN00281-01 Cooling system ........................................................................................................................ 2 Cooling fan pump..................................................................................................................... 4 Cooling fan motor .................................................................................................................... 12 Power train, Part 1 .......................................................................................................... SEN00282-02 Power train............................................................................................................................... 2 HSS system............................................................................................................................. 4 General view of power train unit .............................................................................................. 6 Power train hydraulic piping drawing....................................................................................... 8 Transmission, steering and brake control................................................................................ 10 Damper and universal joint...................................................................................................... 12 Torque converter and PTO ...................................................................................................... 15 Transmission............................................................................................................................ 20 Transmission clutch ECMV...................................................................................................... 36 Main relief valve and torque converter relief valve .................................................................. 42 Lubrication relief valve............................................................................................................. 44 Power train, Part 2 .......................................................................................................... SEN00283-03 Bevel gear shaft, HSS and brake ............................................................................................ 2 Brake valve.............................................................................................................................. 24 Final drive ................................................................................................................................ 30 Undercarriage and frame................................................................................................ SEN00284-04 Main frame............................................................................................................................... 2 Suspension.............................................................................................................................. 4 Track frame and idler cushion.................................................................................................. 10 Idler.......................................................................................................................................... 14 Track roller............................................................................................................................... 16 Carrier roller............................................................................................................................. 20 Sprocket................................................................................................................................... 22 Track shoe ............................................................................................................................... 26
  • 3. 00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 5 Hydraulic system, Part 1................................................................................................. SEN00285-01 Work equipment hydraulic piping diagram .............................................................................. 2 Work equipment control........................................................................................................... 4 Hydraulic tank and filter ........................................................................................................... 6 Scavenging pump.................................................................................................................... 8 Power train and steering lubrication pump .............................................................................. 9 HSS pump ............................................................................................................................... 10 HSS motor............................................................................................................................... 28 Hydraulic system, Part 2................................................................................................. SEN00286-01 Control valve............................................................................................................................ 2 Self pressure reducing valve ................................................................................................... 36 Hydraulic system, Part 3................................................................................................. SEN00287-01 PPC valve (blade lift, blade tilt)................................................................................................ 2 PPC valve (ripper) ................................................................................................................... 8 Electric lever (steering)............................................................................................................ 12 Quick drop valve...................................................................................................................... 16 PPC lock valve ........................................................................................................................ 18 Accumulator............................................................................................................................. 19 Work equipment.............................................................................................................. SEN00288-00 Blade ....................................................................................................................................... 2 Cutting edge and end bit ......................................................................................................... 6 Ripper...................................................................................................................................... 7 Hydraulic cylinder .................................................................................................................... 8 Piston valve ............................................................................................................................. 11 Cab and its attachments ................................................................................................. SEN00289-00 Cab mount............................................................................................................................... 2 Cab.......................................................................................................................................... 3 Air conditioner.......................................................................................................................... 5 Electrical system............................................................................................................. SEN00290-03 Monitor system ........................................................................................................................ 2 Monitor panel........................................................................................................................... 4 Engine control.......................................................................................................................... 13 Engine control system ............................................................................................................. 14 Cooling system control system................................................................................................ 16 System components ................................................................................................................ 18 Palm command control system ............................................................................................... 26 KOMTRAX system .................................................................................................................. 28 Sensor ..................................................................................................................................... 30 Standard service value table Standard service value table........................................................................................... SEN00584-02 Standard service value table for engine .................................................................................. 2 Standard service value table for chassis ................................................................................. 4 30 Testing and adjusting Testing and adjusting, Part 1 .......................................................................................... SEN00585-03 Tools for testing, adjusting, and troubleshooting ..................................................................... 3 Measuring engine speed ......................................................................................................... 6 Measuring intake air pressure (boost pressure) ...................................................................... 8 Measuring exhaust temperature.............................................................................................. 10 Measuring exhaust gas color................................................................................................... 12 Adjusting valve clearance........................................................................................................ 13 Measuring compression pressure ........................................................................................... 16 Measuring blow-by pressure ................................................................................................... 20 Measuring engine oil pressure ................................................................................................ 21 Handling of fuel system devices.............................................................................................. 22 Releasing residual pressure from fuel system......................................................................... 22
  • 4. SEN00055-09 00 Index and foreword 6 D65EX, PX, WX-15E0 Testing fuel pressure................................................................................................................ 23 Testing fuel return and leak amount......................................................................................... 28 Bleeding air from fuel circuit .................................................................................................... 30 Testing fuel circuit for leakage ................................................................................................. 31 Handling of reduced cylinder mode operation ......................................................................... 32 Testing and adjusting air conditioner compressor belt tension ................................................ 33 Adjusting fuel control dial and decelerator pedal..................................................................... 34 Measuring power train oil pressure.......................................................................................... 36 Adjusting transmission speed sensor (replacement procedure).............................................. 40 Simple method to test brake performance............................................................................... 41 Adjusting brake pedal .............................................................................................................. 42 Adjusting parking brake lever .................................................................................................. 44 Emergency escape method when power train has trouble...................................................... 45 Adjusting clearance of idler...................................................................................................... 48 Inspecting wear of sprocket..................................................................................................... 49 Testing and adjusting track shoe tension................................................................................. 49 Testing and adjusting work equipment and HSS oil pressure.................................................. 50 Testing control circuit basic pressure....................................................................................... 53 Measuring PPC valve output pressure .................................................................................... 54 Adjusting work equipment PPC valve play .............................................................................. 56 Measuring internal leakage of work equipment cylinder.......................................................... 58 Bleeding air from work equipment cylinder.............................................................................. 58 Releasing residual pressure in work equipment cylinder......................................................... 59 Checking parts which caused hydraulic drift of blade or ripper................................................ 60 Adjusting work equipment lock lever ....................................................................................... 61 Measuring fan motor speed..................................................................................................... 62 Measuring fan pump circuit pressure....................................................................................... 63 Bleeding air from fan pump...................................................................................................... 64 Adjusting straight tiltdozer........................................................................................................ 65 Testing and adjusting operator cab.......................................................................................... 67 Testing and adjusting, Part 2........................................................................................... SEN00586-01 Special functions of monitor panel (EMMS)............................................................................. 2 Testing and adjusting, Part 3........................................................................................... SEN00587-02 Handling of voltage circuit of engine controller ........................................................................ 2 Adjustment method when controller has been replaced.......................................................... 2 Preparation work for troubleshooting for electric system......................................................... 4 Inspection procedure of diode ................................................................................................. 9 Pm-Clinic service..................................................................................................................... 10 How to start operation of KOMTRAX terminal ......................................................................... 20 Lamp display of KOMTRAX terminal....................................................................................... 24 40 Troubleshooting General information on troubleshooting.......................................................................... SEN00588-04 Points to remember when troubleshooting .............................................................................. 2 How to proceed troubleshooting.............................................................................................. 3 Checks before troubleshooting................................................................................................ 4 Classification and procedures of troubleshooting.................................................................... 5 How to distinguish wire code ................................................................................................... 8 Connection table for connector pin numbers ........................................................................... 12 T- branch box and T- branch adapter table.............................................................................. 48 Troubleshooting by failure code (Display of code), Part 1 .............................................. SEN00589-03 Failure code table .................................................................................................................... 3 Before troubleshooting by failure codes .................................................................................. 10 Contents of troubleshooting table ............................................................................................ 12 Failure code [1500L0] Transmission clutch: Dual engagement............................................... 14 Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF ....... 16 Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON....... 18
  • 5. 00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 7 Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF....... 20 Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON ...... 22 Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF ............... 24 Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON............... 25 Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF .............. 26 Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON.............. 28 Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF............... 30 Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON .............. 32 Failure code [AB00MA] Alternator: Malfunction....................................................................... 34 Failure code [B@BAZG] Engine oil: Oil pressure too low ....................................................... 34 Failure code [B@BCNS] Radiator coolant: Overheat.............................................................. 35 Failure code [B@CENS] Power train oil: Overheat ................................................................. 35 Failure code [B@HANS] Hydraulic oil: Overheat .................................................................... 36 Failure code [CA111] Engine controller: Abnormality in controller........................................... 37 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors: Abnormal speed sensor signal ................................................................. 37 Failure code [CA122] Charge pressure sensor too high: Excessively high voltage detected............................................................ 38 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected .... 40 Failure code [CA131] Decelerator pedal sensor too high: Excessively high voltage detected............................................................ 42 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected... 44 Failure code [CA144] Coolant temperature sensor too high: Excessively high voltage detected............................................................ 46 Failure code [CA145] Coolant temperature sensor too low: Excessively low voltage detected ............................................................. 48 Failure code [CA153] Charge temperature sensor too high: Excessively high voltage detected............................................................ 50 Failure code [CA154] Charge temperature sensor too low: Excessively low voltage detected ............................................................. 52 Failure code [CA155] Charge temperature too high and engine speed derated: Exceeded upper control limit of temperature............................................ 54 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected...... 56 Failure code [CA221] Atmospheric pressure sensor too high: Excessively high voltage detected............................................................ 58 Failure code [CA222] Atmospheric pressure sensor too low: Excessively low voltage detected ............................................................. 60 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected ... 62 Failure code [CA234] Engine over speed: Excessively high speed ........................................ 64 Failure code [CA238] Abnormal power source for Ne speed sensor: Excessively low voltage detected ............................................................. 65 Failure code [CA271] IMV/PCV1 short circuit: Short circuit..................................................... 66 Failure code [CA272] IMV/PCV1 disconnection: Disconnection ............................................. 68 Failure code [CA281] Abnormal supply pump pressure balance: Abnormal pressure feed of fuel ................................................................ 70 Troubleshooting by failure code (Display of code), Part 2 .............................................. SEN00590-04 Failure code [CA322] Injector No. 1 system disconnection or short circuit: disconnection, short circuit ....................................................................... 4 Failure code [CA323] Injector No. 5 system disconnection or short circuit: disconnection, short circuit ....................................................................... 6 Failure code [CA324] Injector No. 3 system disconnection or short circuit: disconnection, short circuit ....................................................................... 8 Failure code [CA325] Injector No. 6 system disconnection or short circuit: disconnection, short circuit ....................................................................... 10 Failure code [CA331] Injector No. 2 system disconnection or short circuit: disconnection, short circuit ....................................................................... 12 Failure code [CA332] Injector No. 4 system disconnection or short circuit: disconnection, short circuit ....................................................................... 14
  • 6. SEN00055-09 00 Index and foreword 8 D65EX, PX, WX-15E0 Failure code [CA342] Engine controller data matching error: matching error.......................... 16 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected ...... 18 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected ... 20 Failure code [CA428] Water detection sensor too high: Excessively high voltage detected ... 22 Failure code [CA429] Water detection sensor too low: Excessively low voltage detected ...... 24 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.............. 26 Failure code [CA441] Power source voltage too low: Excessively low voltage detected......... 28 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit .................................. 30 Failure code [CA449] Common rail pressure too high (2): Excessively high pressure trouble occurred ............................................. 32 Failure code [CA451] Common rail pressure sensor too high: Excessively high voltage detected............................................................ 36 Failure code [CA452] Common rail pressure sensor too low: Excessively low voltage detected ............................................................. 38 Failure code [CA488] Charge temperature too high and torque derated: Exceeded upper control limit of temperature............................................ 40 Failure code [CA553] Common rail pressure too high (1): Excessively high pressure detected ......................................................... 41 Failure code [CA559] Loss of pressure feed from supply pump (1): Loss of pressure feed detected ................................................................ 42 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal........................... 44 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase............ 46 Failure code [CA757] Loss of all engine controller data: Loss of all data ................................ 48 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal.............. 50 Failure code [CA1633] Abnormal KOMNET: Abnormal communication.................................. 52 Failure code [CA2185] Decelerator pedal sensor power source too high: Excessively high voltage detected............................................................ 54 Failure code [CA2186] Decelerator pedal sensor power source too low: Excessively low voltage detected ............................................................. 55 Failure code [CA2249] Loss of pressure feed from supply pump (2): Loss of pressure feed detected ................................................................ 56 Failure code [CA2265] Electric lift pump disconnection: Disconnection .................................. 58 Failure code [CA2266] Electric lift pump short circuit: Short circuit ......................................... 60 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance .................................... 62 Failure code [CA2555] Air intake heater relay disconnection: Disconnection ......................... 64 Failure code [CA2556] Air intake heater relay short circuit: Short circuit................................. 66 Troubleshooting by failure code (Display of code), Part 3 .............................................. SEN00591-01 Failure code [D110KA] Battery relay: Short circuit................................................................... 4 Failure code [D110KB] Battery relay: Disconnection ............................................................... 6 Failure code [D130KA] Neutral safety relay: Disconnection.................................................... 8 Failure code [D130KB] Neutral safety relay: Short circuit........................................................ 10 Failure code [D161KA] Back-up alarm relay: Disconnection................................................... 12 Failure code [D161KB] Back-up alarm relay: Short circuit....................................................... 14 Failure code [DAFRKR] Monitor panel CAN communication: Defective communication ........ 16 Failure code [DAQ0KT] [DB30KT] Steering and transmission controller: Abnormality in controller ........................................................................... 18 Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller: Power source voltage drop and input ................. 20 Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller: Power source voltage drop and input ................. 22 Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input................................ 24 Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input................................ 26 Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection: Inconsistency in model select signal......................................................... 28
  • 7. 00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 9 Failure code [DB2RKR] Steering and transmission controller CAN communication: Defective communication ......................................................................... 30 Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormality in controller ........................................................................... 32 Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller: Power source voltage drop and input ................. 32 Failure code [DAB32KK] [DAQ2KK] Load power source of steering and transmission controller: Power source voltage drop and input ................. 32 Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input................................ 32 Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input................................ 32 Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model selection: Inconsistency in model select signal ........................................................ 32 Failure code [DD12KA] Shift up switch: Disconnection ........................................................... 34 Failure code [DD12KB] Shift up switch: Short circuit............................................................... 36 Failure code [DD13KA] Shift down switch: Disconnection ...................................................... 38 Failure code [DD13KB] Shift down switch: Short circuit .......................................................... 40 Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection ...................... 42 Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit .......................... 44 Failure code [DDN7KA] Pitch control switch: Disconnection................................................... 46 Failure code [DDN7KB] Pitch control switch: Short circuit ...................................................... 48 Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection ...................... 50 Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit .......................... 50 Failure code [DGS1KX] Hydraulic oil temperature sensor: Input signal is out of normal range ........................................................... 52 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection........................... 54 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range ........................................................... 55 Failure code [DK10KA] Fuel dial: Disconnection..................................................................... 56 Failure code [DK10KB] Fuel dial: Short circuit ........................................................................ 58 Failure code [DK30KA] Steering potentiometer (1): Disconnection......................................... 60 Failure code [DK30KB] Steering potentiometer (1): Short circuit ............................................ 62 Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range............... 64 Failure code [DK30KZ] Steering potentiometer: | Disconnection or short circuit (Double failure).......................................... 65 Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal ............................ 65 Failure code [DK31KA] Steering potentiometer (2): Disconnection......................................... 66 Failure code [DK31KB] Steering potentiometer (2): Short circuit ............................................ 68 Failure code [DK40KA] Brake potentiometer: Disconnection .................................................. 70 Failure code [DK40KB] Brake potentiometer: Short circuit...................................................... 71 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range . 72 Failure code [DK55KZ] Forward-reverse potentiometer: Disconnection or short circuit (Double failure).......................................... 73 Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal ............... 74 Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit ............................... 76 Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection............................ 78 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................ 80 Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit ............................... 82 Troubleshooting by failure code (Display of code), Part 4 .............................................. SEN00592-00 Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit ...................................... 3 Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range 5 Failure code [DLT3KA] Transmission output speed sensor: Disconnection ............................ 6 Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................ 7 Failure code [DV00KB] Alarm buzzer: Short circuit................................................................. 8 Failure code [DW5AKA] Pitch control solenoid: Disconnection............................................... 9 Failure code [DW5AKB] Pitch control solenoid: Short circuit .................................................. 10 Failure code [DW5AKY] Pitch control solenoid: Short circuit to power source line ................. 11
  • 8. SEN00055-09 00 Index and foreword 10 D65EX, PX, WX-15E0 Failure code [DW7BKA] Fan reverse solenoid: Disconnection................................................ 12 Failure code [DW7BKB] Fan reverse solenoid: Short circuit ................................................... 13 Failure code [DWN1KA] HSS EPC solenoid right: Disconnection........................................... 14 Failure code [DWN1KB] HSS EPC solenoid right: Short circuit .............................................. 15 Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line ............. 16 Failure code [DWN2KA] HSS EPC solenoid left: Disconnection ............................................. 17 Failure code [DWN2KB] HSS EPC solenoid left: Short circuit................................................. 18 Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line ............... 19 Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection .......................................... 20 Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit.............................................. 21 Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line............. 22 Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection .......................................... 23 Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit.............................................. 24 Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line............. 25 Failure code [DXH4KA] 1st clutch ECMV: Disconnection........................................................ 26 Failure code [DXH4KB] 1st clutch ECMV: Short circuit ........................................................... 27 Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line.......................... 28 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ...................................................... 29 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit.......................................................... 30 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line......................... 31 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection ....................................................... 32 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit........................................................... 33 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line.......................... 34 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection............................................... 35 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit................................................... 36 Failure code [DXH7KY] reverse clutch ECMV: Short circuit to power source line................... 37 Failure code [DXH8KA] Forward clutch ECMV: Disconnection ............................................... 38 Failure code [DXH8KB] Forward clutch ECMV: Short circuit................................................... 39 Failure code [DXH8KY] forward clutch ECMV: Short circuit to power source line................... 40 Troubleshooting of electrical system (E-mode)............................................................... SEN00593-02 Contents of troubleshooting table ............................................................................................ 5 E-1 The engine does not start (the starting motor does not turn) ............................................ 6 E-2 The preheater does not operate........................................................................................ 10 E-3 The monitor panel does not light up at all when the starting switch is turned ON............. 14 E-4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out.................................................................................. 15 E-5 While the engine is running, the battery charge level caution lamp flashes...................... 16 E-6 While the engine is running, the emergency warning item flashes. .................................. 18 E-7 While the preheater is operating, the preheating pilot lamp does not light up. ................. 22 E-8 The coolant temperature gauge does not indicate correctly. ............................................ 24 E-9 The power train oil temperature gauge does not indicate correctly................................... 26 E-10 Hydraulic oil temperature gauge does not indicate properly. .......................................... 29 E-11 Fuel gauge does not indicate properly............................................................................. 32 E-12 Gear speed and engine speed are not indicated properly. ............................................. 33 E-13 The preset mode service meter does not indicate normally............................................ 33 E-14 The warning lamp does not flash or does not go out. ..................................................... 33 E-15 The alarm buzzer does not sound or does not stop........................................................ 34 E-16 Auto shift down is not possible or is not released. .......................................................... 36 E-17 The buzzer cancel switch does not work. ....................................................................... 38 E-18 The information switch does not work............................................................................. 40 E-19 The fan cleaning does not operate or cannot be reset.................................................... 42 E-20 The preset mode does not operate or cannot be reset................................................... 44 E-21 The monitor panel cannot be set in the service mode or cannot be set out of the service mode. ..................................................................................... 46 E-22 The back-up alarm does not sound................................................................................. 48 E-23 The head lamp and rear lamp do not light up. ................................................................ 50 E-24 The horn does not sound or does not stop. .................................................................... 53 E-25 Malfunction of wipers ...................................................................................................... 54
  • 9. 00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 11 E-26 Washer does not spray water ......................................................................................... 70 E-27 The air conditioner does not operate .............................................................................. 76 E-28 KOMTRAX system does not operate normally ............................................................... 80 Troubleshooting of hydraulic and mechanical system (H-mode).................................... SEN00594-00 Contents of troubleshooting table............................................................................................ 3 H-1 There is no travel power (no drawbar pull). ...................................................................... 4 H-2 Machine does not move (at 2nd or 3rd speed)................................................................. 5 H-3 Machine does not move at any gear speed...................................................................... 6 H-4 Machine travels only in one direction, forward or in reverse............................................. 7 H-5 When gear is shifted or travel direction is changed, large time lag is made..................... 8 H-6 Machine cannot be steered (Machine does not turn leftward or rightward)...................... 9 H-7 Steering speed or power is low......................................................................................... 9 H- 8 Brake does not work........................................................................................................ 10 H-9 Overheat of power train oil................................................................................................ 11 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor 12 H-11 All work equipment speeds are slow............................................................................... 12 H-12 Work equipment does not move ..................................................................................... 13 H-13 Blade lift speed is slow or lacks power ........................................................................... 13 H-14 Blade tilt speed is slow or lacks power ........................................................................... 14 H-15 Ripper lift speed is slow or lacks power.......................................................................... 14 H-16 Excessive hydraulic drift of blade lift............................................................................... 15 H-17 Excessive hydraulic drift of blade tilt............................................................................... 15 H-18 Excessive hydraulic drift of ripper lift............................................................................... 16 Troubleshooting of engine (S-mode) .............................................................................. SEN00595-01 Method of using troubleshooting charts................................................................................... 3 S-1 Starting performance is poor. ............................................................................................ 6 S-2 Engine does not start ........................................................................................................ 7 S-3 Engine does not pick up smoothly .................................................................................... 10 S-4 Engine stops during operations ........................................................................................ 11 S-5 Engine does not rotate smoothly ...................................................................................... 12 S-6 Engine lacks output (or lacks power) ................................................................................ 13 S-7 Exhaust smoke is black (imcomplete combustion) ........................................................... 14 S-8 Oil consumption is excessive (or exhaust smoke is blue)................................................. 15 S-9 Oil becomes contaminated quickly ................................................................................... 16 S-10 Fuel consumption is excessive ....................................................................................... 17 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)............................. 18 S-12 Oil pressure drops........................................................................................................... 19 S-13 Oil level rises (water, fuel in oil) ...................................................................................... 20 S-14 Coolant temperature becomes too high (overheating).................................................... 21 S-15 Abnormal noise is made ................................................................................................. 22 S-16 Vibration is excessive ..................................................................................................... 23 50 Disassembly and assembly General information on disassembly and assembly ....................................................... SEN00944-04 How to read this manual.......................................................................................................... 2 Coating materials list ............................................................................................................... 4 Special tool list......................................................................................................................... 7 Sketches of special tools......................................................................................................... 13 Engine and cooling system, Part 1 ................................................................................. SEN00945-03 Removal and installation of fuel supply pump assembly ......................................................... 2 Removal and installation of cylinder head assembly............................................................... 6 Removal and installation of fuel injector assembly.................................................................. 21 Removal and installation of engine front oil seal ..................................................................... 23 Removal and installation of engine rear oil seal ...................................................................... 26 Engine and cooling system, Part 2 ................................................................................. SEN00946-03 Removal and installation of engine assembly ......................................................................... 2 Removal and installation of radiator assembly ........................................................................ 9
  • 10. SEN00055-09 00 Index and foreword 12 D65EX, PX, WX-15E0 Removal and installation of air aftercooler assembly .............................................................. 13 Removal and installation of fan drive assembly....................................................................... 14 Removal and installation of fan motor assembly ..................................................................... 15 Removal and installation of fuel tank assembly....................................................................... 16 Removal and installation of damper assembly ........................................................................ 18 Removal and installation of engine hood assembly................................................................. 19 Power train, Part 1 .......................................................................................................... SEN00947-01 Removal and installation of power train unit assembly............................................................ 2 Disconnection and connection of power train unit assembly................................................... 5 Disassembly and assembly of PTO assembly......................................................................... 9 Disassembly and assembly of torque converter assembly...................................................... 15 Disassembly and assembly of TORQFLOW transmission assembly ...................................... 20 Power train, Part 2 .......................................................................................................... SEN00948-01 Disassembly and assembly of HSS assembly......................................................................... 2 Removal and installation of final drive assembly ..................................................................... 20 Disassembly and assembly of final drive assembly................................................................. 22 Undercarriage and frame, Part 1 .................................................................................... SEN00949-01 Removal and installation of track frame assembly .................................................................. 2 Removal and installation of idler assembly.............................................................................. 4 Disassembly and assembly of idler assembly ......................................................................... 5 Removal and installation of recoil spring assembly ................................................................. 9 Disassembly and assembly of recoil spring assembly............................................................. 10 Removal and installation of track roller assembly.................................................................... 14 Disassembly and assembly of track roller assembly ............................................................... 15 Removal and installation of carrier roller assembly ................................................................. 19 Disassembly and assembly of carrier roller assembly............................................................. 20 Undercarriage and frame, Part 2 .................................................................................... SEN00950-04 Expansion and installation of track shoe assembly (Conventional type track shoe)................ 2 Expansion and installation of track shoe assembly (PLUS type track shoe) ........................... 5 Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)................................................................. 6 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe) .... 19 Field disassembly and assembly of one link (Conventional type track shoe).......................... 32 Field disassembly and assembly of one link (PLUS type track shoe) ..................................... 39 Removal and installation of pivot shaft assembly .................................................................... 44 Removal and installation of equalizer bar assembly................................................................ 45 Disassembly and assembly of equalizer bar side bushing ...................................................... 47 Hydraulic system............................................................................................................. SEN00951-01 Removal and installation of control valve assembly ................................................................ 2 Disassembly and assembly of control valve assembly............................................................ 4 Removal and installation of HSS pump assembly ................................................................... 5 Removal and installation of power train and lubricating oil pump assembly............................ 6 Removal and installation of cooling fan pump assembly ......................................................... 7 Removal and installation of scavenging pump assembly ........................................................ 9 Removal and installation of HSS motor assembly................................................................... 10 Disassembly and assembly of hydraulic cylinder assembly .................................................... 11 Work equipment.............................................................................................................. SEN00952-01 Removal and installation of blade assembly............................................................................ 2 Cab and its attachments ................................................................................................. SEN00953-03 Removal and installation of ROPS guard ................................................................................ 2 Removal and installation of operator’s cab assembly.............................................................. 3 Removal and installation of operator’s cab glass (Stuck glass)............................................... 9 Removal and installation of floor frame assembly ................................................................... 17 Electrical system............................................................................................................. SEN00954-00 Removal and installation of engine controller .......................................................................... 2 Removal and installation of steering and transmission controller assembly............................ 4 Removal and installation of KOMTRAX terminal ..................................................................... 5
  • 11. 00 Index and foreword SEN00055-09 D65EX, PX, WX-15E0 13 90 Diagrams and drawings Hydraulic diagrams and drawings................................................................................... SEN00058-01 Power train hydraulic circuit diagram....................................................................................... 2 Hydraulic circuit diagram ......................................................................................................... 3 Electrical diagrams and drawings................................................................................... SEN00059-02 Electrical circuit diagram.......................................................................................................... 3 Connector list and stereogram ................................................................................................ 19
  • 12. SEN00945-03 50 Disassembly and assembly 2 D65EX, PX, WX-15E0 Engine and cooling system, Part 1 1 Removal and installation of fuel supply pump assembly 1 Special tools Removal k Disconnect the cable from the negative (–) terminal of the battery. a Since the hose band (MIKALOR clamp) cannot be reused, use new one. See [*1]. a The fuel tube connector is new type (To discon- nect it, press its lock from both sides and pull it). See step 22. k The internal parts of the adapters may be damaged when fuel tubes (23), (24) and (25) are removed. Accordingly, replace the adapters with new ones. 1. Close the fuel supply valve from under the fuel tank. 2. Open engine left side cover (1). 3. Remove covers (2) and (3). 4. Remove bracket (4). 5. Disconnect hose (5). [*1] a Make a mark (M) at the tube end of each hose to show the original position of the hose. 6. Loosen adjustment bolt (6) of the air condi- tioner compressor. 7. Loosen the mounting bolt of air conditioner compressor bracket (7). 8. Remove belt (8). [*2] 9. Disconnect air conditioner compressor hose clamp (9). 10. Disconnect wiring harness clamps (10) and (11). 11. Disconnect connector clip (12). 12. Disconnect connector A/C (13). 13. Disconnect ground wire (14). 14. Remove the air conditioner compressor and bracket (7) together. a Do not disconnect the air conditioner com- pressor hose but place it on the track shoe. Symbol Part number Part name Necessity Q’ty N/R Sketch A 1 795-799-1131 Gear t 1 2 795-799-1390 Remover t 1
  • 13. 50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 3 15. Remove high-pressure pipe clamp (15). [*3] 16. Remove right and left bellows (16). [*3] 17. Remove high-pressure pipe (17). [*3] 18. Disconnect lubrication tube (18). [*4] 19. Disconnect clamp (19). 20. Disconnect brackets (20) and (21). [*5] 21. Disconnect connector (22) from the back of bracket (21). 22. Disconnect fuel tube (23). [*6] a While pressing locks (L) at the front and rear of fuel tube (23), pull it down to dis- connect. 23. Disconnect fuel tubes (24) and (25) similarly to fuel tube (23). [*6] 24. Disconnect receiver drier and bracket assem- bly (26). 25. Remove cap (27). 26. Install gear A1 (See the Special tools table) to rotate the crankshaft. a See Testing and adjusting, “Testing and adjusting valve clearance”. 27. Twist off cap (28). a Use a filter wrench etc. to remove the cap. 28. Rotate the crankshaft and set stamp (M) of drive gear (GY) to the top dead center. a Use a mirror. a See Testing and adjusting, “Testing and adjusting valve clearance”. 29. Remove nut (29) and washer (30) from shaft (SH) of the fuel supply pump. a Take care not to drop the nut and washer into the case.
  • 14. SEN00945-03 50 Disassembly and assembly 4 D65EX, PX, WX-15E0 30. Tighten tool A2 evenly to disconnect shaft (SH) of the fuel supply pump from drive gear (GY). 31. Remove bracket (31). 32. Remove 4 nuts (32) and fuel supply pump assembly (33). Installation q Install the fuel supply pump assembly accord- ing to the following procedure. 1. Install fuel supply pump assembly (33), match- ing projection (P) of its shaft SH to groove (G) of gear (GY). 2. Install bracket (31) to fuel supply pump assem- bly (33) and tighten 4 nuts (32). 2 Mounting nut: Adhesive (LT-2) 3 Mounting nut and bracket mounting bolt: 43 ± 6 Nm {4.4 ± 0.6 kgm} 3. Set washer (30) and tighten nut (29). a When installing the nut and washer, take care not to drop them into the case. 3 Nut: 178 ± 13 Nm {18.2 ± 1.3 kgm} q Carry out the following installation in the reverse order to removal.
  • 15. 50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 5 [*1] a Use a new MIKALOR clamp. a Set the hose to the original (marked) position. (Insertion depth of air hose: 57 mm) a Set the bridge (BR) so that its clamp bolt will be at the bottom and it will be lapped over band (BD) as follows. Lapped over band dimension (b) : Min. 5 mm 2 Threads of clamp bolt: Lubricating oil: THREEBOND, PAND18B a Do not use an impact wrench. q When reusing the hose a Set the clamp to its original position. 3 MIKALOR clamp: Min. 6 Nm {0.6 kgm} q When using a new hose a Tighten until band gap (BDG) is 5 – 8 mm. [*2] a See Testing and adjusting, “Testing and adjust- ing air conditioner compressor belt tension”. [*3], [*5] q High-pressure pipe, high-pressure pipe clamp and bracket 1) Tighten bracket (21), high-pressure pipe (17), and clamp (15) in order with the fin- gers. 2) Tighten the sleeve nut of high-pressure pipe (17). 3 Sleeve nut: 37.3 ± 4 Nm {3.8 ± 0.4 kgm} 3) Install right and left bellows (16). 4) Tighten clamp (15) and bracket (21) per- manently in order. [*4] 3 Joint bolt of lubrication tube (18): 24 ± 4 Nm {2.45 ± 0.41 kgm} [*5] See [*3]. [*6] q Fuel tubes (23), (24) and (25) k The internal parts of the adapters may be damaged when fuel tubes (23), (24) and (25) are removed. Accordingly, replace the adapters with new ones.
  • 16. SEN00945-03 50 Disassembly and assembly 6 D65EX, PX, WX-15E0 Removal and installation of cylinder head assembly 1 Special tools Removal k Disconnect the cable from the negative (–) terminal of the battery. a Since the hose band (MIKALOR clamp) cannot be reused, use new one. See [*6]. a The fuel tube connector is new type (To discon- nect it, press its lock from both sides and pull it). See step 21. k The internal parts of the adapters may be damaged when fuel tubes (20) and (61) are removed. Accordingly, replace the adapters with new ones. a The wiring harness connector is new type (To disconnect it, slide the first lock and then press the second lock). See step 26. 1. Remove the engine hood assembly. For details, see “Removal of engine hood assembly”. 2. Drain the coolant. 6 Coolant: Approx. 39 l 3. Remove cover (1). 4. Remove the air hose, tube, and bracket assembly (2). [*1] a If the MIKALOR clamp (MC) is used, do not disconnect the hose. 5. Disconnect dust indicator hose (3). 6. Disconnect air hose (4). [*2] 7. Remove band (5). [*3] 8. Remove air cleaner assembly (6). 9. Remove plate (7). 10. Remove the mounting bolts and lift off muffler assembly (8). 4 Muffler assembly: 25 kg 11. Remove bracket (9). Symbol Part number Part name Necessity Q’ty N/R Sketch A 1 795-799-1131 Gear t 1 3 795-799-6700 Puller t 1 4 795-799-8150 Remover q 1 8 790-331-1120 Wrench (angle) q 1
  • 17. 50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 7 12. Disconnect wiring harness clamp (10). 13. Disconnect terminal HT/A (11) (black). a If the terminal cover is removed from the wiring harness, the label comes off. Accordingly, tape the label. 14. Disconnect terminals (12) (green) and (13) (black and thick). 15. Disconnect connector mounting bolt (14). 16. Disconnect ground terminal (15) (black). a If the terminal cover is removed from the wiring harness, the label comes off. Accordingly, tape the label. In particular, if the labels of terminals HT/A (11) and ground terminal (15) come off, you cannot say which is which, since both terminals HT/A (11) and ground terminal (15) are black and coming from the same wiring harness. 17. Disconnect wiring harness clamp (16). 18. Disconnect bracket (17). 19. Disconnect air cleaner bracket (18). 20. Disconnect coolant hose (19). [*4] a Check the connection end. 21. Press both sides of lock (L) of fuel tube (20) to disconnect. [*5] a Check the connection end. 22. Remove filter and bracket assembly (21). 23. Disconnect air hose (22). [*6] a Make marks at the hose end tube to show the original position of the hose (See the figure below). 24. Disconnect bracket (23). 25. Remove heater relay and plate assembly (24).
  • 18. SEN00945-03 50 Disassembly and assembly 8 D65EX, PX, WX-15E0 26. Disconnect connector (25) according to the fol- lowing procedure. 1) Slide lock (L1) to the right. 2) While pressing lock (L2), pull it toward this side to disconnect. a If part (A) does not float when lock (L2) is pressed and pulled toward this side, the connector is not disconnected. In this case, while pressing lock (L2), float part (A) with a small flat-head screwdriver and pull lock (L2) toward this side. 27. Remove bracket (26). 28. Disconnect ground wire (27). 29. Remove air intake connector and tube assem- bly (28). 30. Loosen adjustment bolt (29) of the air condi- tioner compressor. 31. Loosen the mounting bolt of air conditioner compressor bracket (30). 32. Remove air conditioner compressor belt (31). [*7] 33. Disconnect air conditioner compressor hose clamp (32). 34. Disconnect wiring harness clamp (33). 35. Disconnect connector clip (34). 36. Disconnect connector A/C (35). 37. Disconnect ground wire (36). 38. Remove air conditioner compressor and bracket (30) together. a Do not disconnect the air conditioner com- pressor hose but place it on the track shoe. 39. Disconnect muffler drain tube clamp (37). 40. Remove bracket (38).
  • 19. 50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 9 q View of whole air intake unit 41. Remove high-pressure pipe clamp (39). [*8] 42. Remove right and left bellows (40). [*8] 43. Remove high-pressure pipe (41). [*8] 44. Disconnect connector (42). 45. Disconnect clamps (43) and (44). 46. Disconnect connector (45). 47. Disconnect bracket (46). [*8] 48. Disconnect fuel supply pump connector (47). 49. Disconnect connectors (48) – (50). 50. Disconnect 12 high-pressure pipe bellows (51). [*8] 51. Remove high-pressure pipes (52) – (57). [*8] 52. Disconnect fuel return tube (58). [*8] 53. Remove common rail (59). [*8] a Do not remove the fuel pressure sensor (PS) except for its replacement. 54. Disconnect clamp (60). 55. Disconnect fuel tube (61). [*9] 56. Remove bracket (62). 57. Disconnect clamp (63). 58. Disconnect radiator hoses (64) and (65). [*10]
  • 20. SEN00945-03 50 Disassembly and assembly 10 D65EX, PX, WX-15E0 59. Disconnect bracket (66). 60. Remove heat insulation cover (67). 61. Remove heat insulation covers (68) and (69). 62. Disconnect turbocharger lubrication hose (70). [*11] 63. Disconnect turbocharger lubrication tube (71). [*11] 64. Remove brackets (72) – (77). 65. Sling turbocharger and exhaust manifold assembly (78) temporarily. 66. Remove the mounting bolts and lift off turbo- charger and exhaust manifold assembly (78). [*12] 4 Turbocharger and exhaust manifold assembly: 35 kg 67. Disconnect clamp (79) from the rear of the engine. 68. Remove bracket mounting bolt (80). 69. Disconnect receiver drier and bracket assem- bly (81). 70. Remove cap (82). 71. Install gear A1 (See the Special tools table) to rotate the crankshaft. a See Testing and adjusting, “Testing and adjusting valve clearance”.
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  • 22. 50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 11 72. Twist off cap (83). a Use a filter wrench etc. to remove the cap. 73. Rotate the crankshaft and set stamp (M) of drive gear (GY) to the top dead center. a Use a mirror. a See Testing and adjusting, “Testing and adjusting valve clearance”. 74. Disconnect clamp (84). 75. Disconnect oil hose (85). 76. Remove cover (86). 77. Remove air intake cover (87). [*13] 78. Remove cylinder head cover (88). [*14] a Referring to Testing and adjusting, "Test- ing and adjusting valve clearance", check to see if the No. 1 cylinder is at the top or the No. 6 cylinder is at the top. 79. Disconnect wiring harness (89) from the injec- tor. a Locations of wiring harnesses (*): Reverse connection is also possible. 80. Loosen locknut (90) and then loosen adjust- ment screw (91) 2 – 3 turns. a This work must be performed so that an excessive force will not be applied to the push rod when the rocker arm is installed. 81. Remove mounting bolt (92) and rocker arm and crosshead assembly (93). a Record the position and direction (shapes of holes "a" and "b") of each crosshead. (When reinstall the crosshead, set it in the same direction.) Color of cable Cylinder No. a Yellow (*) 1, 3, 5 b Orange c Red (*) 2, 4, 6 d Brown
  • 23. SEN00945-03 50 Disassembly and assembly 12 D65EX, PX, WX-15E0 82. Remove retainer (95) and inlet connector (96). a Before removing retainer (95), remove all dirt from it and its periphery. a Tool A4 (remove) is set for removal of inlet connector (96). (See Special tools table.) 83. Remove 2 mounting bolts (94) of the injector assembly. 84. Using tool A3, remove injector assembly (97). a Take care that dirt and foreign matter will not enter the mounting part of the fuel injector assembly. 85. Remove push rod (98). 86. Remove spacer (99). 87. Work on the other cylinders similarly. 88. Remove rocker housing assembly (100). 89. Remove the 26 bolts and lift off cylinder head assembly (102). 4 Cylinder head assembly: 85 kg 90. Remove cylinder head gasket (103).
  • 24. 50 Disassembly and assembly SEN00945-03 D65EX, PX, WX-15E0 13 Installation q Cylinder head assembly a Check that there is no dirt and foreign matter on the cylinder head mounting surface and in the cylinders. 1. Set cylinder head gasket (103) to the cylinder block. a Match the holes of the cylinder head gas- ket (103) to the holes of the block. 2. Sling cylinder head assembly (102) and set it to the block. a Check that the collet is fitted to the groove of each valve stem by lightly hitting the valve stem with a plastic hammer. a Check that cylinder head gasket (103) is matched to the holes of the block. 3. Before tightening the cylinder head mounting bolts, check the following. 1) Measure stem length "a" of each mounting bolt and check that it is shorter than the using limit. 2) Using limit length of bolt: 162.6 mm a If a bolt is longer than the using limit, do not reuse it but replace it. 2 Apply engine oil (SAE15W-40) to the threads and seats of the mount- ing bolts. 4. Tighten the mounting bolts by 2 – 3 turns with the fingers, and then tighten them according to the following procedure. 1) Tighten the cylinder head mounting bolts in the order shown below. 1] 150 ± 9.8 Nm {15.3 ± 1.0 kgm} 2] Return all bolts 360° 3] 115 ± 4.9 Nm {11.7 ± 0.5 kgm} 4] Check tightening torque of 115 ± 4.9 Nm {11.7 ± 0.5 kgm} 5] 120° ± 5° q Tool A8 (See the Special tools table) is set for angle tightening. q When not using angle tightening tool A8 Make a mark on the cylinder head and each bolt with paint and then tighten the bolt by 120° ± 5°.