Komatsu D65EX-16 D65PX-16 D65WX-16 Bulldozer Shop Manual PDF

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Komatsu D65EX-16 D65PX-16 D65WX-16 Bulldozer Shop Manual SEN04887-07 – PDF DOWNLOAD

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Komatsu D65EX-16 D65PX-16 D65WX-16 Bulldozer Shop Manual SEN04887-07 – PDF DOWNLOAD 

Language : English
Pages : 293
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Komatsu D65EX-16 D65PX-16 D65WX-16 Bulldozer Shop Manual SEN04887-07 – PDF DOWNLOAD 

SERIAL NUMBERS
D65EX- 80001 and up
D65PX- 80001 and up
D65WX-80001 and up

00 Index and foreword
100 Index SEN04931-07
Composition of shop manual 2
Table of contents 4
200 Foreword and general information SEN04932-01
Safety notice 2
How to read the shop manual 7
Explanation of terms for maintenance standard 9
Handling of electric equipment and hydraulic component 11
Handling of connectors newly used for engines 20
How to read electric wire code 23
Precautions when carrying out operation 26
Method of disassembling and connecting push-pull type coupler 29
Standard tightening torque table 32
Conversion table 36
01 General
100 Specification and technical data SEN04933-01
Specification dimension drawing 2
Specifications 6
Weight table 18
Table of fuel, coolant and lubricants 22
10 Structure, function and maintenance standard
100 Engine and cooling system SEN04963-00
Engine mount 3
Cooling system 4
Cooling fan pump 6
Cooling fan motor 20
201 Power train, Part 1 SEN04964-00
Power train 2
HSS system 4
Overall view of power train unit 6
Power train hydraulic piping diagram 10
Transmission, steering and brake control 12
Damper 14
Universal joint 16
Torque converter and PTO 17
Transmission 24
Transmission control valve 42
ECMV 46
Main relief and torque converter relief valve 54
Transmission lubrication relief valve 56
202 Power train, Part 2 SEN04965-01
Bevel gear shaft, HSS and brake 2
Brake valve 24
Final drive 30
Final drive (Planetary gear installed inside of sprocket type) 36
300 Undercarriage and frame SEN04966-02
Main frame 2
Suspension 4
Track frame and idler cushion 14
Idler 18
Idler (Without idler support automatic thrust adjustment) 20
Carrier roller 26
SEN04931-07
D65EX, PX, WX-16 00-100 5
Table of contents
100 Index
Sprocket 28
Track shoe 32
401 Hydraulic system, Part 1 SEN04967-00
Work equipment hydraulic system layout drawing 2
Work equipment control 6
Hydraulic tank and filter 8
Scavenging pump 10
Power train and steering lubrication pump 11
HSS pump 12
HSS motor 31
402 Hydraulic system, Part 2 SEN04968-01
Control valve 2
CLSS 11
Function and operation of each valve 14
403 Hydraulic system, Part 3 SEN04969-00
PPC valve (blade lift, blade tilt) 2
PPC valve (ripper) 8
Electric lever (steering) 12
Quick drop valve 16
Work equipment lock solenoid valve 18
Pitch selector solenoid valve 22
Hydraulic oil cooler bypass valve 23
Accumulator 24
500 Work equipment SEN04970-00
Blade 2
Cutting edge and end bit 8
Ripper 10
Hydraulic cylinder 11
Piston valve 14
600 Cab and its attachments SEN04971-01
Cab mount 2
Cab 3
FRP canopy mount 4
FRP canopy 5
700 Electrical system SEN04972-01
Monitor system 2
Engine control system 18
Cooling system control system 21
Electronic steering control system 23
KOMTRAX system 26
System components 28
Sensor 36
20 Standard value table
100 Standard service value table SEN05118-01
Standard service value table for engine 2
Standard service value table for chassis 4
30 Testing and adjusting
101 Testing and adjusting, Part 1 SEN05119-02
Tools for testing, adjusting, and troubleshooting 2
Testing engine speed 5
Testing intake air pressure (boost pressure) 7
Testing exhaust temperature 9
Testing exhaust gas color 11
Adjusting valve clearance 12
SEN04931-07
00-100 6 D65EX, PX, WX-16
Table of contents
100 Index
Testing compression pressure 14
Testing blow-by pressure 18
Testing engine oil pressure 19
Handling of fuel system devices 20
Releasing residual pressure from fuel system 20
Testing fuel pressure 21
Testing fuel return and leak amount 26
Bleeding air from fuel circuit 28
Testing fuel circuit for leakage 29
Handling of reduced cylinder mode operation 30
Handling of no injection cranking operation 30
Testing and adjusting air conditioner compressor belt tension 31
Replacing alternator belt 32
Adjusting fuel control dial and decelerator pedal 33
Handling controller high-voltage circuit 34
102 Testing and adjusting, Part 2 SEN05120-02
Testing power train oil pressure 3
Adjusting transmission output shaft speed sensor (replacement procedure) 8
Simple test procedure for brake performance 9
Adjusting brake pedal 10
Adjusting parking brake lever 12
Emergency escape method when power train has trouble 14
Adjusting clearance of idler 17
Adjusting clearance of idler (without idler support automatic thrust adjustment) 18
Inspecting wear of sprocket 19
Testing and adjusting track shoe tension 20
Testing and adjusting work equipment and HSS oil pressure 21
Testing control circuit basic pressure 24
Testing PPC valve output pressure 25
Adjusting work equipment PPC valve play 27
Testing internal leakage of work equipment cylinder 31
Bleeding air from work equipment cylinder 32
Releasing residual pressure from work equipment cylinder 32
Checking parts which caused hydraulic drift of blade or ripper 33
Adjusting work equipment lock lever 34
Adjusting work equipment lock lever (FRP canopy specification) 35
Testing fan speed 37
Testing fan circuit oil pressure 38
Bleeding air from fan pump 39
Bleeding air from HSS pump 40
Adjusting straight tiltdozer 41
Adjusting play of blade center ball 43
Adjusting operator’s cab 44
103 Testing and adjusting, Part 3 SEN05121-02
Special functions of machine monitor (EMMS) 2
104 Testing and adjusting, Part 4 SEN05122-01
Handling of voltage circuit of engine controller 2
Adjustment method when controller has been replaced 3
Preparation work for troubleshooting of electrical system 5
Inspection procedure of diode 9
Pm-Clinic service 10
40 Troubleshooting
100 Failure code table and fuse locations SEN05029-01
Failure codes table 2
Fuse locations 7
SEN04931-07
D65EX, PX, WX-16 00-100 7
Table of contents
100 Index
200General information on troubleshootingSEN05030-01
Points to remember when troubleshooting 2
How to proceed troubleshooting 3
Checks before troubleshooting 4
Classification and procedures for troubleshooting 6
Symptom supposed to be failure and troubleshooting No 10
Information contained in troubleshooting table 12
Troubleshooting method for disconnecting wiring harness of pressure sensor system 14
Connector list and stereogram 16
Connection table for connector pin numbers 30
T- branch box and T- branch adapter table 66
301 Troubleshooting by failure code (Display of code), Part 1 SEN05031-00
Failure code [1500L0] Transmission clutch: Abnormal 3
Failure code [15SAL1] Forward clutch: Fill high 4
Failure code [15SALH] Forward clutch: Fill low 6
Failure code [15SBL1] Reverse clutch: Fill high 8
Failure code [15SBLH] Reverse clutch: Fill low 10
Failure code [15SEL1] Speed 1st clutch: Fill high 12
Failure code [15SELH] Speed 1st clutch: Fill low 14
Failure code [15SFL1] Speed 2nd clutch: Fill high 16
Failure code [15SFLH] Speed 2nd clutch: Fill low 18
Failure code [15SGL1] Speed 3rd clutch: Fill high 20
Failure code [15SGLH] Speed 3rd clutch: Fill low 22
Failure code [15SJL1] L/U: Fill high 24
Failure code [15SJLH] L/U: Fill low 26
Failure code [AB00MA] Battery Charge Abnormal 28
Failure code [B@BAZG] Eng Oil Press Low 30
Failure code [B@BCNS] Eng Water Overheat 30
Failure code [B@CENS] T/C Oil Overheat 31
Failure code [B@HANS] Hyd Oil Overheat 31
302 Troubleshooting by failure code (Display of code), Part 2 SEN05032-01
Failure code [CA111] ECM Critical Internal Failure 3
Failure code [CA115] Eng Ne and Bkup Speed Sens Error 3
Failure code [CA122] Chg Air Press Sensor High Error 4
Failure code [CA123] Chg Air Press Sensor Low Error 6
Failure code [CA131] Throttle Sensor High Error 8
Failure code [CA132] Throttle Sensor Low Error 10
Failure code [CA144] Coolant Temp Sens High Error 12
Failure code [CA145] Coolant Temp Sens Low Error 14
Failure code [CA153] Chg Air Temp Sensor High Error 16
Failure code [CA154] Chg Air Temp Sensor Low Error 18
Failure code [CA155] Chg Air Temp High Speed Derate 20
Failure code [CA187] Sens Supply 2 Volt Low Error 22
Failure code [CA221] Ambient Press Sens High Error 24
Failure code [CA222] Ambient Press Sens Low Error 26
Failure code [CA227] Sens Supply 2 Volt High Error 28
Failure code [CA234] Eng Overspeed 28
Failure code [CA238] Ne Speed Sens Supply Volt Error 29
Failure code [CA271] IMV/PCV1 Short Error 30
Failure code [CA272] IMV/PCV1 Open Error 32
Failure code [CA281] Abnormal supply pump pressure balance 34
Failure code [CA322] Inj #1(L#1) Open/Short Error 36
Failure code [CA323] Inj #5(L#5) Open/Short Error 38
Failure code [CA324] Inj #3(L#3) Open/Short Error 40
Failure code [CA325] Inj #6(L#6) Open/Short Error 42
Failure code [CA331] Inj #2(L#2) Open/Short Error 44
Failure code [CA332] Inj #4(L#4) Open/Short Error 46
SEN04931-07
00-100 8 D65EX, PX, WX-16
Table of contents
100 Index
303Troubleshooting by failure code (Display of code), Part 3SEN05033-01
Failure code [CA342] Calibration Code Incompatibility 3
Failure code [CA351] Injectors Drive Circuit Error 3
Failure code [CA352] Sens Supply 1 Volt Low Error 4
Failure code [CA386] Sens Supply 1 Volt High Error 6
Failure code [CA428] Water in Fuel Sensor High Error 8
Failure code [CA429] Water in Fuel Sensor Low Error 10
Failure code [CA435] Eng Oil Press Sw Error 12
Failure code [CA441] Battery Voltage Low Error 14
Failure code [CA442] Battery Voltage High Error 16
Failure code [CA449] Rail Press Very High Error 18
Failure code [CA451] Rail Press Sensor High Error 20
Failure code [CA452] Rail Press Sensor Low Error 22
Failure code [CA488] Chg Air Temp High Torque Derate 24
Failure code [CA553] Rail Press High Error 25
Failure code [CA559] Rail Press Low Error 26
Failure code [CA689] Eng Ne Speed Sensor Error 28
Failure code [CA731] Eng Bkup Speed Sens Phase Error 32
Failure code [CA757] All Continuous Data Lost Error 33
Failure code [CA778] Eng Bkup Speed Sensor Error 34
Failure code [CA1633] KOMNET Datalink Timeout Error 37
Failure code [CA2185] Throt Sens Sup Volt High Error 38
Failure code [CA2186] Throt Sens Sup Volt Low Error 40
Failure code [CA2249] Rail Press Very Low Error 42
Failure code [CA2265] Fuel Feed Pump Open Error 44
Failure code [CA2266] Fuel Feed Pump Short Error 46
Failure code [CA2311] IMV Solenoid Error 47
Failure code [CA2555] Grid Htr Relay Volt High Error 48
Failure code [CA2556] Grid Htr Relay Volt Low Error 50
304 Troubleshooting by failure code (Display of code), Part 4 SEN05034-01
Failure code [D110KB] Battery relay drive: Short circuit 4
Failure code [D130KA] Neutral relay: Disconnection 6
Failure code [D130KB] Neutral relay: Short circuit 8
Failure code [D161KA] Back-up alarm relay: Disconnection 10
Failure code [D161KB] Back-up alarm relay: Short circuit 12
Failure code [D862KA] GPS Antenna Open Circuit 14
Failure code [DAFRKR] CAN Disconnection 15
Failure code [DAFRMC] CAN Discon (Monitor Detected) 16
Failure code [DB2RKR] CAN Disconnection 19
Failure code [DBE0KT] PT controller: Abnormality in controller 24
Failure code [DBE1KK] Battery direct Source voltage reduction 26
Failure code [DBE2KK] Solenoid Source voltage reduction 28
Failure code [DBE5KK] PT cont : Sensor voltage 5V (1) reduction 30
Failure code [DBE6KK] PT cont : Sensor voltage 24V reduction 32
Failure code [DBE7KK] PT cont : Sensor voltage 5V (2) reduction 34
Failure code [DBE9KQ] PT controller: Type select signal 36
Failure code [DD12KA] Shift up Sw: Disconnection 38
Failure code [DD12KB] Shift up Sw: Short circuit 40
Failure code [DD13KA] Shift down Sw: Disconnection 42
Failure code [DD13KB] Shift down Sw: Short circuit 44
Failure code [DD14KA] Parking lever Sw: Disconnection 46
Failure code [DD14KB] Parking lever Sw: Short circuit 48
305 Troubleshooting by failure code (Display of code), Part 5 SEN05035-00
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection 4
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit 6
Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection 8
Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit 10
Failure code [DDNLKA] Weq lock Sw: Disconnection 12
SEN04931-07
D65EX, PX, WX-16 00-100 9
Table of contents
100 Index
Failure code [DDNLKB] Weq lock Sw: Short circuit 14
Failure code [DGS1KX] Hyd oil temp sensor: Abnormal 16
Failure code [DGT1KA] T/C oil temp sensor: Disconnection 18
Failure code [DGT1KX] T/C oil temp sensor: Short circuit 20
Failure code [DH21KA] Weq pressure sensor: Disconnection 22
Failure code [DH21KB] Weq pressure sensor: Short circuit 24
Failure code [DHT5KA] T/C pressure sensor: Disconnection 26
Failure code [DHT5KB] T/C pressure sensor: Short circuit 28
Failure code [DK10KA] Fuel control Dial: Disconnection 30
Failure code [DK10KB] Fuel control Dial: Short circuit 32
Failure code [DK30KA] ST lever 1: Disconnection 34
Failure code [DK30KB] ST lever 1: Short circuit 36
Failure code [DK30KX] ST lever: Out of normal range 38
Failure code [DK30KZ] ST lever: Disconnection or short circuit 38
Failure code [DK30L8] ST lever: Signal mismatch 39
Failure code [DK31KA] ST lever 2: Disconnection 40
Failure code [DK31KB] ST lever 2: Short circuit 42
Failure code [DK40KA] Brake potentiometer: Disconnection 44
Failure code [DK40KB] Brake potentiometer: Short circuit 46
Failure code [DK55KX] FR lever: Out of normal range 48
Failure code [DK55KZ] FR lever: Disconnection or short circuit 48
Failure code [DK55L8] FR lever: Signal mismatch 49
Failure code [DK56KA] FR lever 1: Disconnection 50
Failure code [DK56KB] FR lever 1: Short circuit 52
Failure code [DK57KA] FR lever 2: Disconnection 54
Failure code [DK57KB] FR lever 2: Short circuit 56
306 Troubleshooting by failure code (Display of code), Part 6 SEN05036-01
Failure code [DKH1KA] Pitch angle sensor: Disconnection 4
Failure code [DKH1KB] Pitch angle sensor: Short circuit 6
Failure code [DLT3KA] T/M out-speed sensor: Disconnection 8
Failure code [DLT3KB] T/M out-speed sensor: Abnormal 9
Failure code [DW5AKA] Pitch selector Sol : Disconnection 10
Failure code [DW5AKB] Pitch selector Sol : Short circuit 11
Failure code [DW5AKY] Pitch selector Sol : Short circuit 12
Failure code [DW7BKA] Fan rev EPC: Disconnection 14
Failure code [DW7BKB] Fan rev EPC: Short circuit 15
Failure code [DWN1KA] Hss EPC1: Disconnection 16
Failure code [DWN1KB] Hss EPC1: Short circuit 17
Failure code [DWN1KY] Hss EPC1: Short circuit 18
Failure code [DWN2KA] Hss EPC2: Disconnection 19
Failure code [DWN2KB] Hss EPC2: Short circuit 20
Failure code [DWN2KY] Hss EPC2: Short circuit 21
Failure code [DWN5KA] Fan pump solenoid: Disconnection 22
Failure code [DWN5KB] Fan pump solenoid: Short circuit 23
Failure code [DWN5KY] Fan control solenoid: Short circuit 24
Failure code [DXA0KA] TVC Sol : Disconnection 26
Failure code [DXA0KB] TVC Sol : Short circuit 27
Failure code [DXA0KY] TVC Sol : Short circuit 28
Failure code [DXH1KA] Lock-up ECMV: Disconnection 29
Failure code [DXH1KB] Lock-up ECMV: Short circuit 30
Failure code [DXH1KY] Lock-up ECMV: Short circuit 32
Failure code [DXH4KA] 1st clutch ECMV: Disconnection 34
Failure code [DXH4KB] 1st clutch ECMV: Short circuit 35
Failure code [DXH4KY] 1st clutch ECMV: Short circuit 36
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection 37
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit 38
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit 39
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection 40
SEN04931-07
00-100 10 D65EX, PX, WX-16
Table of contents
100 Index
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit 41
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit 42
Failure code [DXH7KA] R clutch ECMV: Disconnection 43
Failure code [DXH7KB] R clutch ECMV: Short circuit 44
Failure code [DXH7KY] R clutch ECMV: Short circuit 46
Failure code [DXH8KA] F clutch ECMV: Disconnection 48
Failure code [DXH8KB] F clutch ECMV: Short circuit 49
Failure code [DXH8KY] F clutch ECMV: Short circuit 50
Failure code [DXJ4KA] Weq lock Sol : Disconnection 52
Failure code [DXJ4KB] Weq lock Sol : Short circuit 53
400 Troubleshooting of electrical system (E-mode) SEN05037-01
Before troubleshooting of electrical system 3
Information in troubleshooting table 5
E-1 Engine does not start (starting motor does not turn) 7
E-2 Preheater does not operate 10
E-3 When starting switch is turned ON, machine monitor displays nothing 16
E-4 When starting switch is turned ON (before starting engine), basic check item lights up 18
E-5 Precaution item lights up while engine is running 20
E-6 Emergency stop item lights up while engine is running 22
E-7 Engine coolant temperature gauge does not indicate normally 24
E-8 Fuel gauge does not indicate properly 26
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally 29
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally 30
E-11 Contents of display by machine monitor are different from applicable machine 31
E-12 Machine monitor does not display some items 31
E-13 Function switch does not work 31
E-14 Operation mode does not change 32
E-15 Gearshift mode does not change 32
E-16 Customize function does not operate normally 33
E-17 Customize memory function does not operate normally 33
E-18 Alarm buzzer does not sound or does not stop 34
E-19 When starting switch is turned OFF, service meter is not displayed 34
E-20 Machine monitor cannot be set in service mode 34
E-21 Horn does not sound or does not stop 35
E-22 Back-up alarm does not sound or does not stop 36
E-23 Head lamp or rear lamp does not light up 38
E-24 Windshield wiper does not operate 42
E-25 Window washer does not operate 56
E-26 KOMTRAX system does not operate correctly 61
500 Troubleshooting of hydraulic and mechanical system (H-mode) SEN05038-00
Failure mode and cause table 2
Contents of troubleshooting table 4
H-1 There is no travel power (no drawbar pull) 5
H-2 Machine does not move (at 2nd or 3rd speed) 6
H-3 Machine does not move at any gear speed 7
H-4 Machine travels only in one direction, forward or in reverse 8
H-5 When gear is shifted or travel direction is changed, large time lag is made 9
H-6 Machine cannot be steered (Machine does not turn leftward or rightward) 10
H-7 Steering speed or power is low 10
H- 8 Brake does not work 11
H-9 Overheat of power train oil 12
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor 13
H-11 All work equipment speeds are slow 13
H-12 Work equipment does not move 14
H-13 Blade lift speed is slow or lacks power 14
H-14 Blade tilt speed is slow or lacks power 15
H-15 Ripper lift speed is slow or lacks power 15
H-16 Excessive hydraulic drift of blade lift 16
SEN04931-07
D65EX, PX, WX-16 00-100 11
Table of contents
100 Index
H-17 Excessive hydraulic drift of blade tilt 16
H-18 Excessive hydraulic drift of ripper lift 17
600 Troubleshooting of engine (S-mode) SEN05039-00
Method of using troubleshooting charts 3
S-1 Starting performance is poor 6
S-2 Engine does not start 7
S-3 Engine does not pick up smoothly 10
S-4 Engine stops during operations 11
S-5 Engine does not rotate smoothly 12
S-6 Engine lacks output (or lacks power) 13
S-7 Exhaust smoke is black (incomplete combustion) 14
S-8 Oil consumption is excessive (or exhaust smoke is blue) 15
S-9 Oil becomes contaminated quickly 16
S-10 Fuel consumption is excessive 17
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down) 18
S-12 Oil pressure drops 19
S-13 Oil level rises (water, fuel in oil) 20
S-14 Coolant temperature becomes too high (overheating) 21
S-15 Abnormal noise is made 22
S-16 Vibration is excessive 23
50 Disassembly and assembly
100 General information on disassembly and assembly SEN05110-01
How to read this manual 2
Coating materials list 4
Special tool list 7
Sketches of special tools 17
200 Engine and cooling system SEN05111-00
Removal and installation of fuel supply pump assembly 2
Removal and installation of fuel injector assembly 7
Removal and installation of cylinder head assembly 17
Removal and installation of radiator assembly 32
Removal and installation of aftercooler assembly 35
Removal and installation of hydraulic oil cooler assembly 37
Removal and installation of power train oil cooler assembly 39
Removal and installation of cooling fan drive assembly 42
Removal and installation of cooling fan motor assembly 44
Removal and installation of engine assembly 46
Removal and installation of damper assembly 54
Removal and installation of engine front oil seal 57
Removal and installation of engine rear oil seal 61
Removal and installation of engine hood assembly 69
Removal and installation of fuel tank assembly 71
300 Power train SEN05112-01
Removal and installation of power train unit assembly 2
Separation and connection of power train unit assembly 6
Disassembly and assembly of PTO assembly 11
Disassembly and assembly of torque converter assembly 16
Disassembly and assembly of transmission assembly 27
Disassembly and assembly of HSS assembly 54
Removal and installation of final drive assembly 74
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type) 76
Disassembly and assembly of final drive assembly 78
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type) 86
400 Undercarriage and frame SEN05113-02
Removal and installation of track frame assembly 2
Removal and installation of idler assembly 4
SEN04931-07
00-100 12 D65EX, PX, WX-16
Table of contents
100 Index
Removal and installation of idler assembly (Without idler support automatic thrust adjustment) 6
Disassembly and assembly of idler assembly 8
Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment) 12
Removal and installation of recoil spring assembly 17
Disassembly and assembly of recoil spring assembly 18
Removal and installation of track roller assembly 22
Disassembly and assembly of track roller assembly 23
Removal and installation of carrier roller assembly 27
Disassembly and assembly of carrier roller assembly 28
Expansion and installation of track shoe assembly (Conventional type track shoe) 31
Expansion and installation of track shoe assembly (PLUS type track shoe) 34
Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe) 35
Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe) 49
Field disassembly and assembly of one link (Conventional type track shoe) 61
Field disassembly and assembly of one link (PLUS type track shoe) 68
Removal and installation of pivot shaft assembly 73
Removal and installation of equalizer bar assembly 74
Disassembly and assembly of equalizer bar side bushing 76
500 Hydraulic system SEN05114-00
Removal and installation of hydraulic tank assembly 2
Removal and installation of control valve assembly 5
Disassembly and assembly of control valve assembly 8
Disassembly and assembly of blade lift and tilt PPC valve assembly 10
Disassembly and assembly of ripper PPC valve assembly 11
Removal and installation of HSS and cooling fan pump assembly 12
Removal and installation of power train and lubrication pump assembly 14
Removal and installation of scavenging pump assembly 16
Removal and installation of HSS motor assembly 17
Disassembly and assembly of hydraulic cylinder assembly 20
600 Work equipment SEN05115-00
Removal and installation of blade assembly (ST-TPP dozer) 2
Removal and installation of blade assembly (PAT dozer) 5
Removal and installation of ripper assembly 7
700 Cab and its attachments SEN05116-01
Removal and installation of ROPS cab assembly 2
Removal and installation of FRP canopy (FRP canopy specification) 9
Removal and installation of floor frame assembly (FRP canopy specification) 10
Removal and installation of operator’s cab glass (Stuck glass) 14
Removal and installation of air conditioner unit assembly 20
Removal and installation of air conditioner compressor assembly 24
800 Electrical system SEN05117-00
Removal and installation of monitor panel assembly 2
Removal and installation of engine controller assembly 4
Removal and installation of power train controller assembly 6
Removal and installation of KOMTRAX terminal assembly 8
80 Appendix
100 Air conditioner SEN05041-00
Structure and function 4
Air conditioner component 4
Configuration and function of refrigerating cycle 6
Outline of refrigerating cycle 7
Air conditioner unit 10
Control plate 14
Compressor 15
Condenser 16
Receiver drier 17
SEN04931-07
D65EX, PX, WX-16 00-100 13
Table of contents
100 Index
Testing, adjusting and troubleshooting 18
Caution about refrigerant 18
Troubleshooting procedure 19
Block diagram 20
Circuit diagram and arrangement of connector pins 22
Detail of air conditioner unit 24
Parts and connectors arrangement 26
Testing air leakage (duct) 32
Testing with self-diagnosis function 34
Testing temperature control 37
Testing vent (mode) changeover 39
Testing Recirc/Fresh changeover 42
Testing inner sensor 43
Testing evaporator temperature sensor 44
Testing sunlight sensor 47
Testing (dual) pressure switch for refrigerant 48
Testing relays and diodes 50
Troubleshooting chart 1 52
Troubleshooting chart 2 53
Troubleshooting for electrical system (E mode) 56
E-1 Power supply system (Air conditioner does not operate) 57
E-2 Compressor and refrigerant system (Air is not cooled) 60
E-3 Blower motor system (No air comes out or air flow is abnormal) 63
E-4 Temperature cannot be controlled 66
E-5 Vent (mode) cannot be changed over 68
E-6 Recirc/Fresh air cannot be changed over 70
Troubleshooting with gauge pressure 72
Connection of service tool 75
Precautions for connecting air conditioner piping 76
Handling of compressor oil 77
1 Control of compressor oil (Denso: ND-OIL8: For R134a) 77
2 Adding of compressor oil 77
3 Compressor replacement 78
4 Applying compressor oil for O-ring 78
90 Diagrams and drawings
100 Hydraulic diagrams and drawings SEN04934-00
Power train hydraulic circuit diagram 3
Work equipment hydraulic circuit diagram 5
200 Electrical diagrams and drawings SEN04935-02
Electrical circuit diagram 3
Electrical circuit diagram (sand terrain specification) 23
Electrical circuit diagram (FRP canopy specification) 29

S.V 18/12/24