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Komatsu D65EX-15, D65PX-15, D65WX-15 Crawler Bulldozer Shop Manual SEBM029508 – PDF DOWNLOAD
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Description
Komatsu D65EX-15, D65PX-15, D65WX-15 Crawler Bulldozer Shop Manual
FILE DETAILS:
Komatsu D65EX-15, D65PX-15, D65WX-15 Crawler Bulldozer Shop Manual
Brands: Komatsu
Equipment Type: Crawler Bulldozer
Manuals Type: Shop Manual
Machine Model: D65EX-15, D65PX-15, D65WX-15
Serial Number: 67001 and up
Book Code: SEBM029508
Language: English
Pages: 922
File Format: Portable Document Format (PDF)
DESCRIPTION:
Komatsu D65EX-15, D65PX-15, D65WX-15 Crawler Bulldozer Shop Manual
HOW TO READ THE SHOP MANUAL:
1. Composition of shop manual
This shop manual contains the necessary technical information for services performed in a workshop. For ease of understanding, the manual is divided into the following sections.
00. FOREWORD:
This section explains the safety and basic information.
01. GENERAL:
This section explains the specifications of the machine.
10. STRUCTURE AND FUNCTION, MAINTENANCE STANDARD:
This section explains the structure, function, and maintenance standard values of each component. The structure and function sub-section explains the structure and function of each component. It serves not only to give an understanding of the structure, but also serves as reference material for troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly and service.
20. TESTING AND ADJUSTING:
Standard value table
This section explains the standard values for new machine and judgement criteria for testing, adjusting, and troubleshooting. This standard value table is used to check the standard values in testing and adjusting and to judge parts in troubleshooting.
Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also explained in
the Chassis volume and Engine volume. In this case, see the Chassis volume.
30. DISASSEMBLY AND ASSEMBLY:
This section explains the special tools and procedures for removing, installing, disassembling, and assembling each component, as well as precautions for them. In addition, tightening torque and quantity and weight of coating material, oil, grease, and coolant necessary for the work are also explained.
90. OTHERS (chassis volume)/Repair and replacement of parts (engine volume):
• Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
• Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
TABLE OF CONTENTS:
Komatsu D65EX-15, D65PX-15, D65WX-15 Crawler Bulldozer Shop Manual
COVER.......................................................................................................................................... 1 CONTENTS....................................................................................................................................... 2 01 GENERAL..................................................................................................................................... 34 SPECIFICATION DIMENSIONS................................................................................................................... 35 SPECIFICATIONS............................................................................................................................. 36 WEIGHT TABLE............................................................................................................................... 41 TABLE OF FUEL, COOLANT AND LUBRICANT....................................................................................................... 43 10 STRUCTURE,FUNCTION AND MAINTENANCE STANDARD................................................................................................. 45 COOLING SYSTEM............................................................................................................................. 46 ENGINE MOUNT............................................................................................................................... 48 POWER TRAIN................................................................................................................................ 49 OVERALL DRAWING OF POWER TRAIN UNIT........................................................................................................ 51 HYDRAULIC PIPING OF POWER TRAIN............................................................................................................ 53 DAMPER,UNIVERSAL JOINT..................................................................................................................... 54 TRANSMISSION,STEERING,BRAKE CONTROL........................................................................................................ 56 TORQUE CONVERTER,PTO....................................................................................................................... 58 TRANSMISSION............................................................................................................................... 63 TRANSMISSION ECMV.......................................................................................................................... 74 MAIN RELIEF VALVE.......................................................................................................................... 80 LUBRICATION RELIEF VALVE................................................................................................................... 82 SCAVENGING PUMP............................................................................................................................ 83 POWER TRAIN PUMP,LUBRICATION PUMP.......................................................................................................... 84 HSS SYSTEM................................................................................................................................. 85 HYDRAULIC,HSS PUMP......................................................................................................................... 87 HSS MOTOR..................................................................................................................................105 BEVEL GEAR SHAFT,HSS,BRAKE.................................................................................................................112 BRAKE VALVE................................................................................................................................127 FINAL DRIVE................................................................................................................................132 FRAME ASSEMBLY.............................................................................................................................137 SUSPENSION.................................................................................................................................139 TRACK FRAME, RECOIL SPRING.................................................................................................................145 IDLER......................................................................................................................................149 TRACK ROLLER...............................................................................................................................151 CARRIER ROLLER.............................................................................................................................152 SPROCKET...................................................................................................................................153 TRACK SHOE.................................................................................................................................155 WORK EQUIPMENT HYDRAULIC PIPING DIAGRAM....................................................................................................158 WORK EQUIPMENT CONTROL.....................................................................................................................160 HYDRAULIC TANK.............................................................................................................................162 ACCUMULATOR................................................................................................................................164 PPC LOCK VALVE.............................................................................................................................165 HYDRAULIC CYLINDER.........................................................................................................................166 PISTON VALVE...............................................................................................................................168 QUICK DROP VALVE...........................................................................................................................169 COOLING FAN PUMP...........................................................................................................................171 COOLING FAN MOTOR..........................................................................................................................179 PPC VALVE..................................................................................................................................185 PCCS LEVER.................................................................................................................................195 CONTROL VALVE..............................................................................................................................198 SELF PRESSURE REDUCING VALVE...............................................................................................................230 WORK EQUIPMENT.............................................................................................................................237 CUTTING EDGE,END BIT.......................................................................................................................241 RIPPER.....................................................................................................................................242 CAB MOUNT..................................................................................................................................243 CAB........................................................................................................................................244 AIR CONDITIONER PIPING.....................................................................................................................246 ENGINE CONTROL.............................................................................................................................247 ENGINE CONTROL SYSTEM......................................................................................................................248 CRI ENGINE CONTROL SYSTEM..................................................................................................................250 COOLING SYSTEM CONTROL SYSTEM..............................................................................................................252 PALM COMMAND CONTROL SYSTEM................................................................................................................254 SYSTEM COMPONENTS..........................................................................................................................256 ENGINE CONTROLLER..........................................................................................................................258 TRANSMISSION AND STEERING CONTROLLER.......................................................................................................260 MONITOR SYSTEM.............................................................................................................................262 MONITOR PANEL..............................................................................................................................264 SENSORS....................................................................................................................................268 20 TESTING AND ADJUSTING.......................................................................................................................273 STANDARD VALUE TABLE FOR ENGINE............................................................................................................274 STANDARD VALUE TABLE FOR CHASSIS...........................................................................................................275 TESTING AND ADJUSTING......................................................................................................................283 TOOLS FOR TESTING,ADJUSTING,AND TROUBLESHOOTING........................................................................................285 MEASURING ENGINE SPEED.................................................................................................................287 MEASURING INTAKE AIR PRESSURE (BOOST PRESSURE).........................................................................................289 MEASURING EXHAUST TEMPERATURE..........................................................................................................291 MEASURING EXHAUST GAS COLOR............................................................................................................292 ADJUSTING VALVE CLEARANCE..............................................................................................................294 MEASURING COMPRESSION PRESSURE.........................................................................................................296 MEASURING BLOW-BY PRESSURE.............................................................................................................298 MEASURING ENGINE OIL PRESSURE..........................................................................................................299 HANDLING OF FUEL SYSTEM DEVICES........................................................................................................300 RELEASING RESIDUAL PRESSURE FROM FUEL SYSTEM...........................................................................................300 MEASURING FUEL PRESSURE................................................................................................................301 BLEEDING AIR FROM FUEL CIRCUIT.........................................................................................................302 INSPECTION OF FUEL CIRCUIT FOR LEAKAGE.................................................................................................305 REDUCED CYLINDER MODE OPERATION FOR ENGINE.............................................................................................306 TESTING AND ADJUSTING ALTERNATOR BELT TENSION..........................................................................................307 TESTING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION..........................................................................307 ADJUSTING FUEL CONTROL DIAL AND DECELERATOR PEDAL......................................................................................308 MEASURING POWER TRAIN OIL PRESSURE.....................................................................................................310 ADJUSTING TRANSMISSION SPEED SENSOR (REPLACEMENT PROCEDURE)............................................................................315 SIMPLE METHOD OF TESTING BRAKE PERFORMANCE.............................................................................................316 ADJUSTING BRAKE PEDAL..................................................................................................................317 EMERGENCY ESCAPE METHOD WHEN POWER TRAIN HAS TROUBLE...................................................................................320 ADJUSTING CLEARANCE OF IDLER...........................................................................................................323 INSPECTING WEAR OF SPROCKET............................................................................................................323 TESTING AND ADJUSTING TRACK SHOE TENSION...............................................................................................324 TESTING AND ADJUSTING WORK EQUIPMENT AND HSS OIL PRESSURE..............................................................................325 TESTING CONTROL CIRCUIT MAIN PRESSURE..................................................................................................328 MEASURING PPC VALVE OUTPUT PRESSURE....................................................................................................329 ADJUSTING PLAY OF WORK EQUIPMENT PPC VALVE.............................................................................................331 MEASURING INTERNAL LEAKAGE OF WORK EQUIPMENT CYLINDER..................................................................................332 BLEEDING AIR FROM WORK EQUIPMENT CYLINDER..............................................................................................332 RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (IF PPC ACCUMULATOR IS INSTALLED)...............................................333 RELEASING RESIDUAL PRESSURE IN WORK EQUIPMENT CYLINDER (IF PPC ACCUMULATOR IS NOT INSTALLED)...........................................333 ADJUSTING SAFETY LOCK LEVER............................................................................................................334 MEASURING FAN MOTOR SPEED..............................................................................................................335 MEASURING FAN PUMP CIRCUIT PRESSURE....................................................................................................336 BLEEDING AIR FROM FAN PUMP.............................................................................................................337 ADJUSTING STRAIGHT TILTDOZER...........................................................................................................338 TESTING AND ADJUSTING OPERATOR'S CAB...................................................................................................340 SPECIAL FUNCTIONS OF MONITOR PANEL (EMMS)..............................................................................................344 HANDLING OF HIGH-VOLTAGE CIRCUIT OF ENGINE CONTROLLER..................................................................................382 ADJUSTMENT METHOD OF REPLACED CONTROLLER...............................................................................................382 PREPARATION WORK FOR TROUBLESHOOTING FOR ELECTRIC SYSTEM ..............................................................................384 PM CLINIC SERVICE......................................................................................................................386 UNDERCARRIAGE TROUBLESHOOTING REPORT...................................................................................................393 TROUBLESHOOTING............................................................................................................................395 POINTS TO REMEMBER WHEN TROUBLESHOOTING................................................................................................396 SEQUENCE OF EVENTS IN TROUBLESHOOTING..................................................................................................397 HANDLING OF ELECTRIC EQUIPMENT AND HYDRAULIC COMPONENT.................................................................................398 CHECKS BEFORE TROUBLESHOOTING..........................................................................................................407 CLASSIFICATION AND PROCEDURES OF TROUBLESHOOTING.......................................................................................408 TYPES AND LOCATIONS CONNECTORS (D65EX,PX-15)...........................................................................................411 CONNECTOR ARRANGEMENT DRAWING..........................................................................................................417 CIRCUIT DRAWING FOR ENGINE CONTROLLER SYSTEM (E CIRCUIT)...............................................................................423 CIRCUIT DRAWING FOR STEERING AND TRANSMISSION CONTROLLER SYSTEM (ST・TM CIRCUIT)........................................................425 CIRCUIT DRAWING FOR MONITOR PANEL SYSTEM (M CIRCUIT)...................................................................................427 Connection table for connector pin numbers.............................................................................................429 T- BRANCH BOX AND T- BRANCH ADAPTER TABLE..............................................................................................465 TROUBLESHOOTING WHEN ERROR CODE IS DISPLAYED (ERROR CODE)..............................................................................468 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST......................................................................................473 TROUBLE CODE TABLE.................................................................................................................474 ERROR CODE [1500L0] (TRANSMISSION CLUTCH: SEE THE LIST.(L0)).......................................................................475 ERROR CODE [15SAL1] (FORWARD CLUTCH:SEE THE LIST.(L1)).............................................................................476 ERROR CODE [15SALH] (FORWARD CLUTCH:SEE THE LIST.(LH)).............................................................................477 ERROR CODE [15SBL1] (REVERSE CLUTCH:SEE THE LIST.(L1)).............................................................................478 ERROR CODE [15SBLH] (REVERSE CLUTCH:SEE THE LIST.(LH)).............................................................................479 ERROR CODE [15SEL1] (1ST CLUTCH:SEE THE LIST.(L1)).................................................................................480 ERROR CODE [15SELH] (1ST CLUTCH:SEE THE LIST.(LH)).................................................................................481 ERROR CODE [15SFL1] (2ND CLUTCH:SEE THE LIST.(L1)).................................................................................482 ERROR CODE [15SFLH] (2ND CLUTCH:SEE THE LIST.(LH)).................................................................................483 ERROR CODE [15SGL1] (3RD CLUTCH:SEE THE LIST.(L1)).................................................................................484 ERROR CODE [15SGLH] (3RD CLUTCH:SEE THE LIST.(LH)).................................................................................485 ERROR CODE [A000N1] (ENGINE:OVERRUN (N1))..........................................................................................486 ERROR CODE [AB00MA] (ALTERNATOR:MALFUNCTION (MA))..................................................................................487 ERROR CODE [AD00L2] (COMMON RAIL:SEE THE LIST.(L2))................................................................................487 ERROR CODE [AD00MA] (COMMON RAIL:DEFECTIVE FUNCTION(MA))...........................................................................488 ERROR CODE [AD10L3] (FUEL SUPPLY PUMP:SEE THE LIST.(L3))...........................................................................488 ERROR CODE [AD10MA] (FUEL SUPPLY PUMP:DEFECTIVE FUNCTION (MA)).....................................................................490 ERROR CODE [AD10MB] (FUEL SUPPLY PUMP:FUNCTION REDUCTION (MB)).....................................................................490 ERROR CODE [AD11KA] (FUEL SUPPLY PUMP SOLENOID 1:DISCONNECTION (KA))...............................................................491 ERROR CODE [AD11KB] (FUEL SUPPLY PUMP SOLENOID 1:SHORT CIRCUIT (KB))...............................................................492 ERROR CODE [AD51KA] (FUEL SUPPLY PUMP SOLENOID 2:DISCONNECTION (KA))...............................................................493 ERROR CODE [AD51KB] (FUEL SUPPLY PUMP SOLENOID 2:SHORT CIRCUIT (KB))...............................................................494 ERROR CODE [ADA1KA] (NO.1 INJECTOR SOLENOID:DISCONNECTION (KA))....................................................................495 ERROR CODE [ADAZKB] (NO.1.2,AND 3 INJECTOR SOLENOIDS:SHORT CIRCUIT (KB))...........................................................496 ERROR CODE [ADB1KA] (NO.2 INJECTOR SOLENOID:DISCONNECTION (KA))....................................................................498 ERROR CODE [ADC1KA] (NO.3 INJECTOR SOLENOID:DISCONNECTION (KA))....................................................................499 ERROR CODE [ADD1KA] (NO.4 INJECTOR SOLENOID:DISCONNECTION (KA))....................................................................500 ERROR CODE [ADDZKB] (NO.4.5,AND 6 INJECTOR SOLENOIDS:SHORT CIRCUIT (KB))...........................................................501 ERROR CODE [ADE1KA] (NO.5 FUEL INJECTOR SOLENOID:DISCONNECTION(KA))................................................................503 ERROR CODE [ADF1KA] (NO.6 FUEL INJECTOR SOLENOID:DISCONNECTION(KA))................................................................504 ERROR CODE [B@BAZG] (ENGINE OIL: OIL PRESSURE REDUCTION (ZG))......................................................................505 ERROR CODE [B@BCNS] (RADIATOR COOLANT: OVERHEAT (NS))..............................................................................505 ERROR CODE [B@CENS] (POWER TRAN OIL: OVERHEAT (NS))................................................................................506 ERROR CODE [B@HANS] (HYDRAULIC OIL: OVERHEAT (NS)).................................................................................506 ERROR CODE [D110KA] (BATTERY RELAY:DISCONNECTION(KA))..............................................................................507 ERROR CODE [D110KB] (BATTERY RELAY:DISCONNECTION (KB)).............................................................................508 ERROR CODE [D13OKA] (NEUTRAL SAFETY RELAY: SHORT CIRCUIT (KA)).....................................................................509 ERROR CODE [D13OKB] (NEUTRAL SAFETY RELAY: DISCONNECTION (KB)).....................................................................511 ERROR CODE [D161KA] (BACK-UP ALARM RELAY: SHORT CIRCUIT (KA))......................................................................513 ERROR CODE [D161KB] (BACK-UP ALARM RELAY:DISCONNECTION (KB)).......................................................................515 ERROR CODE [D182KZ] (PREHEATER RELAY COIL: DISCONNECTION OR SHORT CIRCUIT (KZ))....................................................517 ERROR CODE [D1D0KB] (ENGINE CONTROLLER LOAD POWER SUPPLY RELAY : SHORT CIRCUIT (KB))...............................................519 ERROR CODE [D5ZFKA] (TRANSMISSION NEUTRAL SIGNAL: DISCONNECTION (KA))..............................................................521 ERROR CODE [D5ZFKB] (TRANSMISSION NEUTRAL SIGNAL:SHORT CIRCUIT(KB))................................................................522 ERROR CODE [DAFRKR] (MONITOR PANEL CAN COMMUNICATION: DEFECTIVE COMMUNICATION (KR).................................................523 ERROR CODE [DAQ0KK] [DB30KK] (STEERING AND TRANSMISSION CONTROLLER:SOURCE VOLTAGE REDUCTION/INPUT (KK))............................525 ERROR CODE [DAQ0KT] (STEERING AND TRANSMISSION CONTROLLER:ABNORMALITY IN CONTROLLER(KT))...........................................526 ERROR CODE [DAQ5KK] [DB35KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 5V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK)).....527 ERROR CODE [DAQ6KK] [DB36KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK))....529 ERROR CODE [DAQ9KQ] [DB39KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION:TYPE SELECT SIGNAL INSISTENCY (KQ))..............530 ERROR CODE [DB3RKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (KR))..........................531 ERROR COED [DB20KQ] (ENGINE CONTROLLER TYPE COLLATION:TYPE SELECT CODE INCONSISTENCY (KQ)).........................................533 ERROR CODE [DB20KT] (ENGINE CONTROLLER :ABNORMALITY IN CONTROLLER (KT))............................................................534 ERROR CODE [DB22KK] (ENGINE CONTROLLER LOAD POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK))......................................535 ERROR CODE [DB29KQ] (ENGINE CONTROLLER TYPE SELECT:TYPE SELECT SIGNAL INCONSISTENCY (KQ))..........................................537 ERROR CODE [DB2AMA] (FUEL INJECTION AMOUNT ADJUSTMENT SWITCH SIGNAL:MALFUNCTION (MA))..............................................538 ERROR CODE [DB2RKR] (STEERING AND TRANSMISSION CONTROLLER CAN COMMUNICATION :DEFECTIVE COMMUNICATION (KR)).........................539 ERROR CODE [DB2RMC] (ENGINE CONTROLLER CAN COMMUNICATION:DEFECTIVE COMMUNICATION (MC)).............................................541 ERROR CODE [DB30KK] [DAQ0KK] (STEERING AND TRANSMISSION CONTROLLER:SOURCE VOLTAGE REDUCTION/INPUT (KK).............................543 ERROR CODE [DB35KK] [DAQ5KK] (STEERING AND TRANSMISSION CONTROLLER ENSOR 5V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK).......543 ERROR CODE [DB36KK] [DAQ6KK] (STEERING AND TRANSMISSION CONTROLLER SENSOR 24V POWER SUPPLY:SOURCE VOLTAGE REDUCTION/INPUT (KK).....543 ERROR CODE [DB39KQ] [DAQ9KQ] (STEERING AND TRANSMISSION CONTROLLER TYPE COLLATION: TYPE SELECT SIGNAL INCONSISTENCY (KQ)...........543 ERROR CODE [DD11KB] (STARTING SWITCH:SHORT CIRCUIT (KB))...........................................................................544 ERROR CODE [DD12KA] (SHIFT UP SWITCH:DISCONNECTION (KA))...........................................................................545 ERROR CODE [DD12KB] (SHIFT UP SWITCH:SHORT CIRCUIT (KB))...........................................................................547 ERROR CODE [DD13KA] (SHIFT DOWN SWITCH:DISCONNECTION (KA)).........................................................................549 ERROR CODE [DD13KB] (SHIFT DOWN SWITCH:SHORT CIRCUIT (KB)).........................................................................551 ERROR CODE [DD14KA] [DDQ2KA] (PARKING LEVER SWITCH:DISCONNECTION (KA)).............................................................553 ERROR CODE [DD14KB] [DDQ2KB] (PARKING LEVER SWITCH:SHORT CIRCUIT(KB))..............................................................555 ERROR CODE [DDE2L6] (ENGINE OIL PRESSURE SWITCH:REFER TO TABLE (L6))...............................................................557 ERROR CODE [DDN7KA] (PITCH CONTROL SWITCH:DISCONNECTION (KA))......................................................................559 ERROR CODE [DDN7KB] (PITCH CONTROL SWITCH:SHORT CIRCUIT (KB))......................................................................561 ERROR CODE [DDQ2KA] [DD14KA] (PARKING LEVER SWITCH:DISCONNECTION (KA)).............................................................563 ERROR CODE [DDQ2KB] [DD14KB] (PARKING LEVER SWITCH:SHORT CIRCUIT (KB)).............................................................563 ERROR CODE [DGE2KX] (ENGINE WATER TEMPERATURE SENSOR (FOR HIGH TEMPERATURE): INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).............564 ERROR CODE [DGE3L6] (ENGINE WATER TEMPERATURE SENSOR (FOR LOW TEMPERATURE):SEE TABLE (L6)).........................................565 ERROR CODE (DGE4KX] (FUEL TEMPERATURE SENSOR:INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).............................................566 ERROR CODE [DGS1KX] (HYDRAULIC OIL TEMPERATURE SENSOR: INPUT SIGNAL IS OUT OF NORMAL RANGE(KX))....................................567 ERROR CODE [DH30KX] (BOOST PRESSURE SENSOR:INPUT IS OUT OF NORMAL RANGE(KX)).......................................................569 ERROR CODE [DH40KX] (COMMON RAIL PRESSURE SENSOR:INPUT IS OUT OF NORMAL RANGE(KX)).................................................571 ERROR CODE [DK10KX] (FUEL CONTROL DIAL:INPUT IS OUT OF NORMAL RANGE (KX))..........................................................573 ERROR CODE [DK12KX] (DECELERATION POTENTIOMETER:INPUT IS OUT OF NORMAL RANGE (KX)).................................................575 ERROR CODE [DK30KA] (STEERING POTENTIOMETER 1: DISCONNECTION (KA)).................................................................577 ERROR CODE [DK30KB] (STEERING POTENTIOMETER 1: SHORT CIRCUIT (KB)).................................................................578 ERROR CODE [DK30KX] (STEERING POTENTIOMETER :INPUT SIGNAL IS OUT OF NORMAL RANGE (KX)).............................................579 ERROR CODE [DK30KZ] (STEERING POTENTIOMETER :DISCONNECTION OR SHORT CIRCUIT (DOUBLE TROUBLE)(KZ))..................................579 ERROR CODE [DK30L8] (STEERING POTENTIOMETER 1 : SEE TABLE(L8)).....................................................................580 ERROR CODE [DK31KA] (STEERING POTENTIOMETER 2:SHORT CIRCUIT (KA))..................................................................581 ERROR CODE [DK31KB] (STEERING POTENTIOMETER 2:DISCONNECTION (KB))..................................................................582 ERROR CODE [DK40KA] (BRAKE POTENTIOMETER : DISCONNECTION(KA))......................................................................583 ERROR CODE [DK40KB] (BRAKE POTENTIOMETER : SHORT CIRCUIT(KB))......................................................................584 ERROR CODE [DK55KX] (FORWARD-REVERSE POTENTIOMETER: INPUT SIGNAL IS OUT OF NORMAL RANGE (KX))......................................585 ERROR CODE [DK55KZ] (FORWARD-REVERSE POTENTIOMETER: DISCONNECTION OR SHORT CIRCUIT (DOUBLE TROUBLE) (KZ))..........................585 ERROR CODE [DK55L8] (FORWARD-REVERSE POTENTIOMETER: SEE TABLE (L8))................................................................586 ERROR CODE [DK56KA] (FORWARD-REVERSE POTENTIOMETER 1:SHORT CIRCUIT (KA))...........................................................587 ERROR CODE [DK56KB] (FORWARD-REVERSE POTENTIOMETER 1:DISCONNECTION (KB))...........................................................589 ERROR CODE [DK57KA] (FORWARD-REVERSE POTENTIOMETER 2 :SHORT CIRCUIT (KA))..........................................................591 ERROR CODE [DK57KB] (FORWARD-REVERSE POTENTIOMETER 2 :DISCONNECTION (KB))..........................................................593 ERROR CODE [DKH1KA] (PITCH ANGLE SENSOR : SHORT CIRCUIT (KA))......................................................................595 ERROR CODE [DKH1KB] (PITCH ANGLE SENSOR : DISCONNECTION (KB))......................................................................596 ERROR CODE [DLE3LC] (ENGINE NE SPEED SENSOR :SEE TABLE (LC)).......................................................................597 ERROR CODE [DLF1KA] (TRANSMISSION OUTPUT SPEED SENSOR :DISCONNECTION (KA)).........................................................598 ERROR CODE [DLH1LC] (ENGINE G SPEED SENSOR :SEE TABLE (LC))........................................................................599 ERROR CODE [DV00KB] (CAUTION BUZZER: SHORT CIRCUIT (KB))...........................................................................600 ERROR CODE [DW5AKA] (PITCH CONTROL SOLENOID : DISCONNECTION (KA))..................................................................601 ERROR CODE [DW5AKB] (PITCH CONTROL SOLENOID: SHORT CIRCUIT (KB))...................................................................602 ERROR CODE [DW7BKA] (FAN REVERSE SOLENOID : DISCONNECTION (KA))....................................................................603 ERROR CODE [DW7BKB] (FAN REVERSE SOLENOID : SHORT CIRCUIT (KB))....................................................................604 ERROR CODE [DWN1KA] (HSS EPC SOLENOID LEFT : DISCONNECTION (KA))...................................................................605 ERROR CODE [DWN1KB] (HSS EPC SOLENOID LEFT : SHORT CIRCUIT (KB))...................................................................606 ERROR CODE [DWN2KA] (HSS EPC SOLENOID LEFT: DISCONNECTION (KA))....................................................................607 ERROR CODE [DWN2KB] (HSS EPC SOLENOID LEFT: SHORT CIRCUIT (KB))....................................................................608 ERROR CODE [DWN5KA] (FAN PUMP TVC SOLENOID : DISCONNECTION (KA))...................................................................609 ERROR CODE [DWN5KB] (FAN PUMP TVC SOLENOID :SHORT CIRCUIT (KB))....................................................................610 ERROR CODE [DXH4KA] (1ST CLUTCH ECMV: DISCONNECTION (KA))..........................................................................611 ERROR CODE [DXH4KB] (1ST CLUTCH ECMV: SHORT CIRCUIT (KB))..........................................................................612 ERROR CODE [DXH5KA] (2ND CLUTCH ECMV: DISCONNECTION (KA))..........................................................................613 ERROR CODE [DXH5KB] (2ND CLUTCH ECMV:SHORT CIRCUIT (KB))...........................................................................614 ERROR CODE [DXH6KA] (3RD CLUTCH ECMV: DISCONNECTION (KA))..........................................................................615 ERROR CODE [DXH6KB] (3RD CLUTCH ECMV:SHORT CIRCUIT (KB))...........................................................................616 ERROR CODE [DXH7KA] (REVERSE CLUTCH ECMV: DISCONNECTION (KA))......................................................................617 ERROR CODE [DXH7KB] (REVERSE CLUTCH ECMV:SHORT CIRCUIT (KB)).......................................................................618 ERROR CODE [DXH8KA] (FORWARD CLUTCH ECMV: DISCONNECTION (KA))......................................................................619 ERROR CODE [DXH8KB] (FORWARD CLUTCH ECMV:SHORT CIRCUIT (KB)).......................................................................620 TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)..........................................................................................621 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST......................................................................................622 E-1 THE ENGINE DOES NOT START......................................................................................................623 E-2 THE PREHEATER DOES NOT OPERATE.................................................................................................626 E-3 THE MONITOR PANEL DOES NOT COME ON AT ALL WHEN THE STARTING SWITCH TURNED ON...................................................628 E-4 WHEN THE STARING SWITCH IS TURNED ON,THE MONITOR PANEL COMPLETELY REMAINS LIGHTED AND DOES NOT GO OUT..........................629 E-5 WHILE THE ENGINE IS OPERATING,THE BATTERY CHARGE LEVEL CAUTION LAMP FLASHES....................................................630 E-6 WHILE THE ENGINE IS OPERATING,THE EMERGENCY WARNING ITEM FLASHES...............................................................632 E-7 WHILE THE PREHEATER IS OPERATING,THE PREHEATING PILOT LAMP DOES NOT COME ON....................................................635 E-8 THE ENGINE WATER TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY..................................................................637 E-9 INDICATION OF THE POWER TRAIN TEMPERATURE GAUGE IS ABNORMAL....................................................................638 E-10 THE HYDRAULIC OIL TEMPERATURE GAUGE DOES NOT INDICATE NORMALLY................................................................639 E-11 INDICATION OF THE FUEL GAUGE IS ABNORMAL......................................................................................640 E-12 INDICATION OF GEAR SPEED AND ENGINE SPEED ARE ABNORMAL........................................................................641 E-13 INDICATION OF THE PRESET MODE SERVICE METER IS ABNORMAL.......................................................................641 E-14 THE WARNING LAMP DOES NOT FLASH OR DOES NOT GO OUT............................................................................641 E-15 THE ALARM BUZZER DOES NOT SOUND OR DOES NOT STOP..............................................................................642 E-16 AUTO SHIFT DOWN IS NOT POSSIBLE OR IS NOT RELEASED............................................................................643 E-17 THE BUZZER CANCEL SWITCH DOES NOT WORK........................................................................................644 E-18 THE INFORMATION SWITCH DOES NOT WORK..........................................................................................645 E-19 THE PRESET MODE DOES NOT OPERATE OR CANNOT BE RESET...........................................................................646 E-20 THE MONITOR PANEL CANNOT BE SET IN THE SERVICE MODE OR CANNOT BE SET OUT THE SERVICE MODE.....................................647 E-21 THE BACK-UP ALARM DOES NOT SOUND..............................................................................................649 E-22 THE HEAD LAMP AND REAR LAMP DO NOT LIGHT UP...................................................................................650 E-23 MALFUNCTION OF WIPERS.........................................................................................................652 E-24 WASHING WATER DOES NOT COME OUT...............................................................................................668 E-25 THE AIR CONDITIONER DOES NOT OPERATE..........................................................................................673 TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)............................................................................678 INFORMATION DESCRIBED IN TROUBLESHOOTING LIST......................................................................................679 H-1 NO TRAVEL POWER (NO DRAWBAR PULL)..............................................................................................680 H-2 MACHINE DOES NOT MOVE (AT 2ND OR 3RD SPEED)....................................................................................681 H-3 MACHINE DOES NOT MOVE IN ANY SPEED RANGE.......................................................................................682 H-4 MACHINE TRAVELS ONLY IN ONE DIRECTION FORWARD OR IN REVERSE....................................................................683 H-5 WHEN GEAR IS SHIFTED OR TRAVEL DIRECTION IS CHANGED,LARGE TIME LAG IS MADE.....................................................684 H-6 MACHINE DOES NOT TURN (NOT TURNED RIGHTWARD OR LEFTWARD).......................................................................685 H-7 STEERING SPEED OR POWER IS LOW.................................................................................................685 H-8 BRAKE DOES NOT WORK............................................................................................................686 H-9 OVERHEAT OF POWER TRAIN OIL TEMPERATURE........................................................................................686 H-10 ABNORMAL SOUND COMES OUT FROM AROUND HSS AND WORK EQUIPMENT PUMP OR HSS MOTOR.................................................687 H-11 ALL WORK EQUIPMENT SPEEDS ARE SLOW............................................................................................687 H-12 WOEK EQUIPMENT DOES NOT MOVE .................................................................................................688 H-13 BLADE LIFT SPEED IS SLOW OR LACKS POWERS......................................................................................688 H-14 BLADE TILT SPEED IS SLOW OR LACKS POWER.......................................................................................689 H-15 RIPPER LIFT SPEED IS SLOW OR LACKS POWER......................................................................................689 H-16 EXCESSIVE HYDRAULIC DRIFT OF BLADE LIFT.......................................................................................690 H-17 EXCESSIVE HYDRAULIC DRIFT OF BLADE TILT.......................................................................................690 H-18 EXCESSIVE HYDRAULIC DRIFT OF RIPPER LIFT......................................................................................691 TROUBLESHOOTING OF ENGINE SYSTEM (S-MODE)..............................................................................................692 METHOD OF USING TROUBLESHOOTING CHARTS.............................................................................................693 S-1 STARING PERFORMANCE IS POOR (STARTING ALWAYS TAKES TIME).......................................................................697 S-2 ENGINE DOES NOT START..........................................................................................................698 S-3 ENGINE DOES NOT PICK UP SMOOTHLY (FOLLOW-UP IS POOR) ..........................................................................701 S-4 ENGINE STOPS DURING OPERATIONS.................................................................................................702 S-5 ENGINE DOES NOT ROTATE SMOOTHLY (HUNTING)......................................................................................703 S-6 ENGINE LACKS OUTPUT (OR LACKS POWER)...........................................................................................704 S-7 EXHAUST SMOKE IS BLACK (INCOMPLETE COMBUSTION).................................................................................705 S-8 OIL CONSUMPTION IS EXCESSIVE (OR EXHAUST SMOKE IS BLUE)........................................................................706 S-9 OIL BECOMES CONTAMINATED QUICKLY...............................................................................................707 S-10 FUEL CONSUMPTION IS EXCESSIVE.................................................................................................708 S-11 OIL IS IN COOLING WATER (OR WATER SPURTS BACK,OR WATER LEVEL GOES DOWN).......................................................709 S-12 OIL PRESSURE CAUTION LAMP LIGHTS UP (DROP IN OIL PRESSURE) ...................................................................710 S-13 OIL LEVEL RISES (WATER,FUEL IN OIL)...........................................................................................711 S-14 WATER TEMPERATURE BECOMES TOO HIGH (OVERHEATING)..............................................................................712 S-15 ABNORMAL NOISE IS MADE........................................................................................................713 S-16 VIBRATION IS EXCESSIVE........................................................................................................714 30 DISASSEMBLY AND ASSEMBLY....................................................................................................................715 HOW TO READ THIS MANUAL....................................................................................................................718 Removal and installation of assemblies.................................................................................................718 Disassembly and assembly of assemblies.................................................................................................719 COATING MATERIALS LIST.....................................................................................................................720 SPECIAL TOOL LIST..........................................................................................................................723 SKETCHES OF SPECIAL TOOLS..................................................................................................................727 REMOVAL AND INSTALLATION OF FUEL SUPPLY PUMP ASSEMBLY......................................................................................729 SPECIAL TOOL...........................................................................................................................729 REMOVAL................................................................................................................................729 INSTALLATION...........................................................................................................................731 REMOVAL AND INSTALLATION OF ENGINE HOOD ASSEMBLY...........................................................................................734 REMOVAL................................................................................................................................734 INSTALLATION...........................................................................................................................734 REMOVAL AND INSTALLATION OF FUEL INJECTOR ASSEMBLY.........................................................................................735 REMOVAL................................................................................................................................735 INSTALLATION...........................................................................................................................736 REMOVAL AND INSTALLATION OF NOZZLE TIP.....................................................................................................739 SPECIAL TOOL ..........................................................................................................................739 REMOVAL................................................................................................................................739 INSTALLATION...........................................................................................................................740 REMOVAL AND INSTALLATION OF ENGINE FRONT SEAL..............................................................................................741 SPECIAL TOOL...........................................................................................................................741 REMOVAL ...............................................................................................................................741 INSTALLATION...........................................................................................................................741 REMOVAL AND INSTALLATION OF DAMPER ASSEMBLY................................................................................................742 REMOVAL................................................................................................................................742 INSTALLATION...........................................................................................................................742 REMOVAL AND INSTALLATION OF ENGINE REAR SEAL...............................................................................................743 SPECIAL TOOL...........................................................................................................................743 REMOVAL ...............................................................................................................................743 INSTALLATION...........................................................................................................................743 REMOVAL AND INSTALLATION OF CYLINDER HEAD ASSEMBLY.........................................................................................746 SPECIAL TOOL...........................................................................................................................746 REMOVAL................................................................................................................................746 INSTALLATION...........................................................................................................................749 REMOVAL AND INSTALLATION OF FUEL TANK ASSEMBLY.............................................................................................751 REMOVAL................................................................................................................................751 INSTALLATION...........................................................................................................................752 REMOVAL AND INSTALLATION OF RADIATOR ASSEMBLY..............................................................................................753 REMOVAL................................................................................................................................753 INSTALLATION...........................................................................................................................754 REMOVAL AND INSTALLATION OF ENGINE ASSEMBLY................................................................................................755 REMOVAL................................................................................................................................755 INSTALLATION...........................................................................................................................758 REMOVAL AND INSTALLATION OF POWER TRAIN UNIT ASSEMBLY......................................................................................760 REMOVAL................................................................................................................................760 INSTALLATION...........................................................................................................................762 DISCONNECTION AND CONNECTION OF POWER TRAIN UNIT ASSEMBLY .................................................................................763 DISCONNECTION..........................................................................................................................763 CONNECTION.............................................................................................................................766 DISASSEMBLY AND ASSEMBLY OF TORQFLOW TRANSMISSION ASSEMBLY.................................................................................767 SPECIAL TOOL...........................................................................................................................767 DISASSEMBLY............................................................................................................................767 ASSEMBLY...............................................................................................................................774 DISASSEMBLY AND ASSEMBLY OF HSS ASSEMBLY...................................................................................................785 SPECIAL TOOL...........................................................................................................................785 DISASSEMBLY ...........................................................................................................................785 ASSEMBLY...............................................................................................................................792 DISASSEMBLY AND ASSEMBLY OF PTO ASSEMBLY...................................................................................................803 DISASSEMBLY............................................................................................................................803 ASSEMBLY...............................................................................................................................805 DISASSEMBLY AND ASSEMBLY OF TORQUE CONVERTER ASSEMBLY......................................................................................809 DISASSEMBLY............................................................................................................................809 ASSEMBLY...............................................................................................................................811 REMOVAL AND INSTALLATION OF SCAVENGING PUMP ASSEMBLY.......................................................................................814 REMOVAL................................................................................................................................814 INSTALLATION...........................................................................................................................814 REMOVAL AND INSTALLATION OF HSS PUMP ASSEMBLY..............................................................................................815 REMOVAL................................................................................................................................815 INSTALLATION...........................................................................................................................815 REMOVAL AND INSTALLATION OF COOLING FAN PUMP ASSEMBLY......................................................................................816 REMOVAL................................................................................................................................816 INSTALLATION...........................................................................................................................817 REMOVAL AND INSTALLATION OF POWER TRAIN AND LUBRICATING OIL PUMP ASSEMBLY..................................................................818 REMOVAL................................................................................................................................818 INSTALLATION...........................................................................................................................818 REMOVAL AND INSTALLATION OF MOTOR ASSEMBLY.................................................................................................819 REMOVAL................................................................................................................................819 INSTALLATION...........................................................................................................................819 REMOVAL AND INSTALLATION OF FINAL DRIVE ASSEMBLY...........................................................................................820 SPECIAL TOOL...........................................................................................................................820 REMOVAL................................................................................................................................820 INSTALLATION...........................................................................................................................821 DISASSEMBLY AND ASSEMBLY OF FINAL DRIVE ASSEMBLY ..........................................................................................822 SPECIAL TOOL...........................................................................................................................822 DISASSEMBLY............................................................................................................................822 ASSEMBLY...............................................................................................................................825 REMOVAL AND INSTALLATION OF TRACK FRAME ASSEMBLY...........................................................................................829 REMOVAL................................................................................................................................829 INSTALLATION...........................................................................................................................830 REMOVAL AND INSTALLATION OF IDLER ASSEMBLY.................................................................................................831 REMOVAL................................................................................................................................831 INSTALLATION...........................................................................................................................831 DISASSEMBLY AND ASSEMBLY OF IDLER ASSEMBLY.................................................................................................832 SPECIAL TOOL...........................................................................................................................832 DISASSEMBLY............................................................................................................................832 ASSEMBLY...............................................................................................................................833 REMOVAL AND INSTALLATION OF RECOIL SPRING ASSEMBLY.........................................................................................836 REMOVAL................................................................................................................................836 INSTALLATION...........................................................................................................................836 DISASSEMBLY AND ASSEMBLY OF RECOIL SPRING ASSEMBLY.........................................................................................837 SPECIAL TOOL...........................................................................................................................837 DISASSEMBLY............................................................................................................................837 ASSEMBLY...............................................................................................................................839 REMOVAL AND INSTALLATION OF TRACK ROLLER ASSEMBLY..........................................................................................841 REMOVAL ...............................................................................................................................841 INSTALLATION...........................................................................................................................841 DISASSEMBLY AND ASSEMBLY OF TRACK ROLLER ASSEMBLY .........................................................................................842 SPECIAI TOOL...........................................................................................................................842 DISASSEMBLY............................................................................................................................842 ASSEMBLY...............................................................................................................................843 REMOVAL AND INSTALLATION OF CARRIER ROLLER ASSEMBLY........................................................................................846 REMOVAL................................................................................................................................846 INSTALLATION...........................................................................................................................846 DISASSEMBLY AND ASSEMBLY OF CARRIER ROLLER ASSEMBLY .......................................................................................847 SPECIAL TOOL...........................................................................................................................847 DISASSEMBLY............................................................................................................................847 ASSEMBLY...............................................................................................................................848 EXPANSION AND INSTALLATION OF TRACK SHOE ASSEMBLY..........................................................................................850 CHECK BEFORE EXPANDING TRACK SHOE ASSEMBLY.............................................................................................850 EXPANSION OF TRACK SHOE ASSEMBLY (ORDINARY)............................................................................................850 EXPANSION TRACK SHOE ASSEMBLY (WHEN TRACK FRAME HAS INTERNAL TROUBLE)..................................................................851 INSTALLATION...........................................................................................................................852 WHOLE DISASSEMBLY AND WHOLE ASSEMBLY OF TRACK SHOE ASSEMBLY ...............................................................................853 SPECIAL TOOL...........................................................................................................................853 WHOLE DISASSEMBLY......................................................................................................................853 WHOLE ASSEMBLY.........................................................................................................................856 FIELD DISASSEMBLY AND ASSEMBLY OF ONE LINK.................................................................................................868 SPECIAL TOOL...........................................................................................................................868 DISASSEMBLY............................................................................................................................868 ASSEMBLY...............................................................................................................................869 REMOVAL AND INSTALLATION OF PIVOT SHAFT ASSEMBLY..........................................................................................875 SPECIAL TOOL...........................................................................................................................875 REMOVAL................................................................................................................................875 INSTALLATION...........................................................................................................................875 REMOVAL AND INSTALLATION OF EQUALIZER BAR ASSEMBLY.........................................................................................876 SPECIAL TOOL...........................................................................................................................876 REMOVAL................................................................................................................................876 INSTALLATION...........................................................................................................................877 DISASSEMBLY AND ASSEMBLY OF EQUALIZER BAR SIDE BUSHING.....................................................................................878 DISASSEMBLY............................................................................................................................878 ASSEMBLY...............................................................................................................................878 REMOVAL AND INSTALLATION OF CONTROL VALVE ASSEMBLY.........................................................................................879 REMOVAL................................................................................................................................879 INSTALLATION...........................................................................................................................880 DISASSEMBLY AND ASSEMBLY OF CONTROL VALVE ASSEMBLY.........................................................................................881 ASSEMBLY...............................................................................................................................881 DISASSEMBLY AND ASSEMBLY OF HYDRAULIC CYLINDER ASSEMBLY....................................................................................882 SPECIAL TOOL...........................................................................................................................882 DISASSEMBLY ...........................................................................................................................882 ASSEMBLY...............................................................................................................................884 REMOVAL AND INSTALLATION OF BLADE ASSEMBLY.................................................................................................888 REMOVAL................................................................................................................................888 INSTALLATION...........................................................................................................................889 REMOVAL AND INSTALLATION OF ROPS GUARD.....................................................................................................890 REMOVAL................................................................................................................................890 INSTALLATION...........................................................................................................................890 REMOVAL AND INSTALLATION OF OPERATOR'S CAB ASSEMBLY........................................................................................891 REMOVAL................................................................................................................................891 INSTALLATION...........................................................................................................................893 REMOVAL AND INSTALLATION OF OPERATOR'S CAB GLASS (STUCK GLASS).............................................................................896 SPECIAL TOOL...........................................................................................................................897 REMOVAL................................................................................................................................897 INSTALLATION...........................................................................................................................898 REMOVAL AND INSTALLATION OF FLOOR FRAME ASSEMBLY...........................................................................................904 REMOVAL................................................................................................................................904 INSTALLATION...........................................................................................................................908 REMOVAL AND INSTALLATION OF STEERING AND TRANSMISSION CONTROLLER ASSEMBLY..................................................................909 REMOVAL................................................................................................................................909 INSTALLATION...........................................................................................................................909 REMOVAL AND INSTALLATION OF ENGINE CONTROLLER ASSEMBLY.....................................................................................910 REMOVAL................................................................................................................................910 INSTALLATION...........................................................................................................................910 REMOVAL AND INSTALLATION OF FAN DRIVE ASSEMBLY.............................................................................................911 REMOVAL................................................................................................................................911 INSTALLATION...........................................................................................................................911 REMOVAL AND INSTALLATION OF FAN MOTOR ASSEMBLY ............................................................................................912 REMOVAL................................................................................................................................912 INSTALLATION...........................................................................................................................912 90 OTHERS......................................................................................................................................913 POWER TRAIN HYDRAULIC CIRCUIT DIAGRAM......................................................................................................914 WORK EQUIPMENT HYDRAULIC CIRCUIT DIAGRAM...................................................................................................915 ELECTRICAL CIRCUIT DIAGRAM (1/6)...........................................................................................................916 ELECTRICAL CIRCUIT DIAGRAM (2/6)...........................................................................................................917 ELECTRICAL CIRCUIT DIAGRAM (3/6)...........................................................................................................918 ELECTRICAL CIRCUIT DIAGRAM (4/6)...........................................................................................................919 ELECTRICAL CIRCUIT DIAGRAM (5/6)...........................................................................................................920 ELECTRICAL CIRCUIT DIAGRAM (6/6)...........................................................................................................921 CAB ELECTRICAL CIRCUIT DIAGRAM.............................................................................................................922
KOMATSU D65EX-15, D65PX-15, D65WX-15 CRAWLER BULLDOZER SHOP MANUAL SEBM029508 – PDF DOWNLOAD:
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