Komatsu D65EX-15,D65PX-15,D65WX-15 Bulldozer Shop Manual SEBM029508 PDF
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Komatsu D65EX-15,D65PX-15,D65WX-15 Bulldozer Shop Manual SEBM029508 – PDF DOWNLOAD
- D65EX-15 67001 and up
- D65PX-15 67001 and up
- D65WX-15 67001 and up
Description
Komatsu D65EX-15,D65PX-15,D65WX-15 Bulldozer Shop Manual SEBM029508 – PDF DOWNLOAD
FILE DETAILS:
Komatsu D65EX-15,D65PX-15,D65WX-15 Bulldozer Shop Manual SEBM029508 – PDF DOWNLOAD
Language : English
Pages : 922
Downloadable : Yes
File Type : PDF
IMAGES PREVIEW OF THE MANUAL:
TABLE OF CONTENTS:
Komatsu D65EX-15,D65PX-15,D65WX-15 Bulldozer Shop Manual SEBM029508 – PDF DOWNLOAD
- D65EX-15 67001 and up
- D65PX-15 67001 and up
- D65WX-15 67001 and up
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
DESCRIPTION:
Komatsu D65EX-15,D65PX-15,D65WX-15 Bulldozer Shop Manual SEBM029508 – PDF DOWNLOAD
- D65EX-15 67001 and up
- D65PX-15 67001 and up
- D65WX-15 67001 and up
Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully BEFORE operating the machine.
1. Before carrying out any greasing or repairs, read all the precautions given on the decals which are fixed to the machine.
2. When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
Always wear safety glasses when hitting. parts with a hammer.
Always wear safety glasses when grinding parts with a grinder, etc.
3. If welding repairs are needed, always have a trained, experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, glasses, cap and other clothes suited for welding work.
4. When carrying out any operation with two or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR signs on the controls in the operator’s compartment.
5. Keep all tools in good condition and learn the correct way to use them.
PREPARATIONS FOR WORK:
7. Before adding oil or making any repairs, park the machine on hard, level ground, and block the wheels or tracks to prevent the machine from moving.
8. Before starting work, lower blade, ripper, bucket or any other work equipment to the ground. If this is not possible, insert the safety pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them.
9. When disassembling or assembling, sup- port the machine with blocks, jacks or stands before starting work.
10. Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, ladders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing.
11. When removing the oil filler cap, drain plug or hydraulic pressure measuring plugs, loosen them slowly to prevent the oil from spurting out.
Before disconnecting or removing components of the oil, water or air circuits, first remove the pressure completely from the circuit.
12. The water and oil in the circuits are hot when the engine is stopped, so be careful not to get burned.
Wait for the oil and water to cool before carrying out any work on the oil or water circuits.
13. Before starting work, remove the leads from the battery. Always remove the lead from the negative (-) terminal first.
14. When raising heavy components, use a hoist or crane.
Check that the wire rope, chains and hooks are free from damage.
Always use lifting equipment which has ample capacity.
Install the lifting equipment at the correct places. Use a hoist or crane and operate slowly to prevent the component from hit- ting any other part. Do not work with any part still raised by the hoist or crane.
15. When removing covers which are under internal pressure or under pressure from a spring, always leave two bolts in position on opposite sides. Slowly release the pressure, then slowly loosen the bolts to remove.
16. When removing components, be careful not to break or damage the wiring. Damaged wiring may cause electrical fires.
17. When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips on to the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip, or can even start fires.
18. As a general rule, do not use gasoline to wash parts. In particular, use only the mini- mum of gasoline when washing electrical parts.
G.B 28/12/24
