Komatsu D65EX-15E0 D65PX-15E0 D65WX-15E0 Bulldozer Shop Manual 2008 PDF Download

Description

Komatsu D65EX-15E0, D65PX-15E0, D65WX-15E0 Bulldozer Shop Manual — SEN00046-06

This is the complete Komatsu Shop Manual for the D65EX-15E0, D65PX-15E0 and D65WX-15E0 bulldozers, serial numbers 69001 and up. It is the full workshop reference — not a summary, not an excerpt — covering everything from the SAA6D114E-3 diesel engine through to final drive and electrical circuit diagrams. Each major section carries its own Form Number so you can see exactly what is included in this PDF.

File Details

• Manual type: Shop Manual
• Brand: Komatsu
• Models covered: D65EX-15E0, D65PX-15E0, D65WX-15E0
• Serial numbers: D65EX-15E0 69001 and up; D65PX-15E0 69001 and up; D65WX-15E0 69001 and up
• Document number: SEN00046-06
• Language: English
• Pages: 1,214
• Format: PDF
• Date: 2008

Chapters Covered

• 00 Index and foreword
• 01 Specification
• 10 Structure, function and maintenance standard
• 20 Standard value table
• 30 Testing and adjusting
• 40 Troubleshooting
• 50 Disassembly and assembly
• 90 Diagrams and drawings

00 — Index and Foreword

Safety notice, how to read the shop manual, explanation of terms for maintenance standard, handling of electric equipment and hydraulic components, handling of connectors newly used for engines, how to read electric wire code, precautions when carrying out operation, method of disassembling and connecting push-pull type couplers, standard tightening torque table, and conversion table.

01 — Specification

Specification dimensions, specifications, weight table, and a table of fuel, coolant and lubricants. The specification chapter covers all three model variants — D65EX-15E0, D65PX-15E0 and D65WX-15E0 — with machine weights, engine rated output, travel speeds, ground pressure, overall dimensions and work equipment specifications.

10 — Structure, Function and Maintenance Standard

The largest section of the manual, covering the engine and cooling system (cooling fan pump, cooling fan motor), power train (HSS system, transmission, torque converter and PTO, transmission clutch ECMV, main relief valve and torque converter relief valve, lubrication relief valve, brake valve, final drive), undercarriage and frame, hydraulic system (control valve, self pressure reducing valve, PPC valve, electric lever, quick drop valve, PPC lock valve, accumulator), work equipment (blade, cutting edge and end bit, ripper, hydraulic cylinder, piston valve), cab and its attachments, and electrical system (monitor system, engine control, cooling system control, palm command control system, KOMTRAX system, sensors).

20 — Standard Value Table

Standard service values for engine and chassis. Engine values cover rotation speed, boost pressure, exhaust gas colour, exhaust temperature, valve clearance, compression pressure, blow-by pressure, oil pressure, oil temperature and belt tension. Chassis values cover engine speed, torque converter stall speed, control lever and pedal strokes, operating efforts, power train oil pressures, brake pressures, HSS pressures, travel speeds, work equipment oil pressures and speeds, time lag, hydraulic drift, cylinder leakage, HSS motor leakage and cooling fan speeds.

30 — Testing and Adjusting

Tools for testing, adjusting and troubleshooting; measuring engine speed, intake air pressure, exhaust temperature and exhaust gas colour; adjusting valve clearance; measuring compression pressure, blow-by pressure and engine oil pressure; handling of fuel system devices; testing fuel pressure, fuel return and leak amount; bleeding air from the fuel circuit; testing the fuel circuit for leakage; handling of reduced cylinder mode operation; testing and adjusting air conditioner compressor belt tension; adjusting fuel control dial and decelerator pedal; measuring power train oil pressure; adjusting the transmission speed sensor; simple method to test brake performance; adjusting brake pedal and parking brake lever; emergency escape method when power train has trouble; adjusting clearance of idler; inspecting wear of sprocket; testing and adjusting track shoe tension; testing and adjusting work equipment and HSS oil pressure; testing control circuit basic pressure; measuring PPC valve output pressure; adjusting play of work equipment PPC valve; measuring internal leakage of work equipment cylinder; bleeding air from work equipment cylinder; releasing residual pressure in work equipment cylinder; checking parts which caused hydraulic drift of blade or ripper; adjusting work equipment lock lever; measuring fan motor speed; measuring fan pump circuit pressure; bleeding air from fan pump; adjusting straight tiltdozer; and testing and adjusting operator cab. This section also includes special functions of the monitor panel (EMMS), handling of the voltage circuit of the engine controller, adjustment method when a controller has been replaced, preparation work for troubleshooting the electric system, inspection procedure of diode, Pm-Clinic service, and KOMTRAX terminal procedures.

40 — Troubleshooting

General information on troubleshooting, including points to remember, how to proceed, checks before troubleshooting, classification and procedures, how to distinguish wire code, connection table for connector pin numbers, and T-branch box and adapter table.

Troubleshooting by failure code is presented in four parts. It covers transmission clutch dual engagement; forward, reverse, 1st, 2nd and 3rd clutch fill signals; alternator; engine oil pressure; radiator coolant overheat; power train oil overheat; hydraulic oil overheat; engine controller; engine Ne and Bkup speed sensors; charge pressure sensor; decelerator pedal sensor; coolant temperature sensor; charge temperature sensor; sensor power sources; atmospheric pressure sensor; engine overspeed; IMV/PCV1; supply pump pressure balance; injector circuits; engine controller data matching; water detection sensor; engine oil pressure switch; power source voltage; common rail pressure; charge temperature; supply pump pressure; engine Ne speed sensor; engine Bkup speed sensor phase; loss of engine controller data; KOMNET; decelerator pedal sensor power source; electric lift pump; IMV solenoid; air intake heater relay; battery relay; neutral safety relay; backup alarm relay; monitor panel CAN communication; steering and transmission controller; shift up/down switches; parking brake lever switch; pitch control switch; hydraulic oil temperature sensor; power train oil temperature sensor; fuel dial; steering potentiometer; brake potentiometer; forward-reverse potentiometer; pitch angle sensor; transmission output speed sensor; alarm buzzer; pitch control solenoid; fan reverse solenoid; HSS EPC solenoids; fan pump TVC solenoid; HSS pump TVC solenoid; and clutch ECMV solenoids.

Troubleshooting of the electrical system (E-mode) covers engine start, preheater, monitor panel, battery charge level, emergency warning items, gauges, gear speed display, service meter, warning lamp, alarm buzzer, auto shift down, buzzer cancel switch, information switch, fan cleaning, preset mode, service mode, backup alarm, lamps, horn, wipers, washers, air conditioner and KOMTRAX.

Troubleshooting of the hydraulic and mechanical system (H-mode) covers travel power, machine movement, direction, gear shift time lag, steering, brake, power train oil overheat, abnormal sound from HSS, work equipment speeds, and blade and ripper hydraulic drift.

Troubleshooting of the engine (S-mode) covers starting performance, engine not starting, pick-up, stalling, smooth running, output, exhaust smoke, oil consumption, oil contamination, fuel consumption, coolant contamination, oil pressure, oil level, coolant temperature, abnormal noise and vibration.

50 — Disassembly and Assembly

General information on disassembly and assembly, coating materials list, special tool list and sketches of special tools. Detailed procedures are given for the engine and cooling system (fuel supply pump, cylinder head, fuel injector, engine front and rear seals, engine assembly, radiator, air aftercooler, fan drive, fan motor, fuel tank, damper, engine hood), power train (power train unit, PTO, torque converter, TORQFLOW transmission, HSS, final drive), undercarriage and frame (track frame, idler, recoil spring, track roller, carrier roller, track shoe), hydraulic system (control valve, HSS pump, power train and lubricating oil pump, cooling fan pump, scavenging pump, HSS motor, hydraulic cylinders), work equipment (blade), cab and its attachments (ROPS guard, operator’s cab, cab glass, floor frame), and electrical system (engine controller, steering and transmission controller, KOMTRAX terminal).

90 — Diagrams and Drawings

Hydraulic diagrams and drawings, including the power train hydraulic circuit diagram and the hydraulic circuit diagram, plus electrical diagrams and drawings including the electrical circuit diagram and the connector list and stereogram.

Why This Shop Manual Matters for Your D65

The D65EX-15E0, D65PX-15E0 and D65WX-15E0 are complex machines with a hydrostatic steering system, an electronically controlled transmission with ECMV clutch control, a common rail fuel system on the SAA6D114E-3 engine, and a temperature-controlled cooling fan circuit. Guessing at pressures, tolerances or wiring is expensive. This manual gives you the manufacturer’s own procedures and values — the same information a Komatsu workshop uses.

With this PDF you can:

• Diagnose fault codes across the engine, transmission, steering and monitor systems, and follow the troubleshooting flowcharts to root cause.
• Carry out engine work — valve clearance, compression testing, injector removal, cylinder head service — to the correct torque and sequence.
• Test and adjust power train oil pressures, HSS pressures, PPC valve output, control circuit basic pressure, brake pressures and fan circuit pressure.
• Remove, disassemble, assemble and reinstall major components: transmission, torque converter, HSS unit, final drive, hydraulic cylinders, track frame and recoil spring.
• Set track shoe tension, idler clearance, sprocket wear limits and blade adjustments.
• Read the hydraulic and electrical circuit diagrams for the complete machine.
• Look up standard service values and repair limits for the chassis and engine.

Every procedure is written for the technician working on the machine — with special tools identified, coating materials listed, tightening torques stated and safety points called out. Whether you are running a D65 on a site, rebuilding a final drive in the workshop, or chasing an intermittent electrical fault, the manual tells you how the system works, what to measure, and what the numbers should be.

IMAGES PREVIEW

The manual is delivered as an instant PDF download. No shipping, no waiting. Open it on any phone, tablet, laptop or desktop, and print the pages you need for the workshop. One download gives you the complete 1,214-page Komatsu D65EX-15E0 / D65PX-15E0 / D65WX-15E0 shop manual.