Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual SEN06715-10

Description

Komatsu D65EX-18, D65PX-18, D65WX-18 Bulldozer Shop Manual (SEN06715-10)

This Komatsu D65EX-18 D65PX-18 D65WX-18 Bulldozer Shop Manual is the complete service and repair documentation for the D65EX-18, D65PX-18, and D65WX-18 bulldozer models equipped with the Komatsu SAA6D114E-6 diesel engine. Published under document number SEN06715-10, this Komatsu D65 bulldozer shop manual covers every major system on these machines, from engine and cooling to power train, undercarriage, hydraulic systems, electrical circuits, and the advanced Urea SCR exhaust aftertreatment system. Whether you are performing routine maintenance, diagnosing a fault code, or rebuilding a major component, this manual provides the technical depth required for professional service work.

File Details

• Manual Type: Shop Manual (Service, Repair, and Maintenance)
• Brand: Komatsu
• Models Covered: D65EX-18, D65PX-18, D65WX-18
• Engine: Komatsu SAA6D114E-6 diesel engine
• Document Number: SEN06715-10
• Language: English
• Format: PDF (instant download)
• Serial Numbers: D65EX-91310, D65PX-91310 and up, D65WX-91310

Chapters Covered

This Komatsu D65EX-18 D65PX-18 D65WX-18 shop manual is organised into the following major sections, each containing detailed procedures, specifications, and reference data:

• 00 Index and Foreword – Abbreviation list, foreword, safety notices, precautions to prevent fire, procedures if fire occurs, waste material disposal, engine technology for exhaust gas emission, precautions for DEF, handling hydraulic equipment, disconnecting and connecting pipings, handling electrical equipment, handling fuel system equipment, handling intake system equipment, practical use of KOMTRAX, push-pull type couplers, Deutsch connectors, slide lock connectors, lock-to-pull connectors, lock-to-push connectors, rotating housing connectors, electric cable codes, maintenance standard terms, standard tightening torque table, conversion table
• 01 Specifications – Specification drawings, specifications, weight table, table of fuel, coolant, and lubricants
• 10 Structure and Function – Urea SCR system (layout, diagram, function, component parts), boot-up system, system operating lamp system, battery disconnect switch, engine system (layout, engine control, automatic idle stop, component parts, damper, VGT, EGR system, EGR valve, EGR cooler, KCCV system, KCCV ventilator, KDPF), cooling system (layout, specifications, cooling fan control system, cooling fan pump, cooling fan motor, hydraulic oil cooler bypass valve), control system (layout, machine monitor system, KOMTRAX system, component parts), hydraulic system (layout, CLSS, component parts, hydraulic tank, work equipment and HSS pump, LS valve, PC valve, PC-EPC valve, control valve), power train system (layout, operation, transmission/steering/brake control, PCCS, HSS system, centralized pressure pickup port, component parts, universal joint, power train mount, torque converter and PTO, lockup clutch ECMV, transmission, transmission control valve, ECMV, relief valves, bevel gear shaft, HSS, brake, brake valve, final drive, scavenging pump, steering lubrication pump, HSS motor, electric steering lever), work equipment system (work equipment control, layout drawings, self-pressure reducing valve, work equipment lock solenoid valve, blade PPC valve, ripper PPC valve, blade pitch selector solenoid valve, pilot circuit accumulator, angle control EPC valve, quick drop valve, piston valve), undercarriage and frame (main frame, suspension, track frame and idler cushion), work equipment (front work equipment structures, fixed multi-shank ripper), CAB related parts (ROPS CAB, CAB mount)
• 20 Standard Value Table – Engine standard values for D65EX-18, D65PX-18, D65WX-18, machine standard values for each model, machine posture and procedures to measure performance, standard value table for electricity
• 30 Testing and Adjusting – Engine and cooling system (examine engine speed, boost pressure, exhaust gas temperature, exhaust gas color, mass air flow and temperature sensor, valve clearance, compression pressure, blowby pressure, engine oil pressure, EGR valve and VGT oil pressure, fuel pressure, fuel discharge/return/leakage, bleed air from fuel system, fuel circuit leakage, cylinder cut-out mode, no-injection cranking, air conditioner compressor belt tension, alternator belt, automatic tensioner, soot accumulation correction, SCR related functions, clean DEF tank, clean DEF pump, adjust decelerator pedal), power train (examine power train oil pressure, adjust transmission output shaft speed sensor, examine brake performance, adjust brake pedal, adjust parking brake lever, move machine by parking brake release), undercarriage and frame (adjust idler clearance, examine and adjust track tension), hydraulic system (release remained pressure, examine and adjust work equipment and HSS oil pressure, examine control circuit oil pressure, examine PPC valve outlet pressure, bleed air from HSS pump, examine and adjust PPC valve play, examine cooling fan speed, examine cooling fan circuit oil pressure, bleed air in cooling fan pump, examine hydraulic drift causes, examine oil leakage from work equipment cylinder, bleed air from work equipment cylinders), work equipment (adjust work equipment lock lever), CAB related parts (examine and adjust operator cab), electrical system (set and operate machine monitor, KOMTRAX startup and shutdown, adjust power train controller, adjust rearview camera angle, handle voltage circuit of engine controller, handle battery disconnect switch, examine diodes), Pm Clinic (Pm Clinic service, check sheets for D65EX-18, D65PX-18, D65WX-18, and undercarriage check sheets)
• 40 Troubleshooting – Precautions before work, abbreviation list, related information (general troubleshooting points, troubleshooting points for Urea SCR system, sequence of events, checks before troubleshooting, inspection procedure, test in accordance with testing procedure, preparation for troubleshooting of electrical system, procedure for troubleshooting, symptom and troubleshooting numbers, information shown in troubleshooting table, how to diagnose wiring harness for open circuit of pressure sensor system, connector list and layout for KOMTRAX terminal and Gateway Function Controller machines, connector contact connection table, T-branch box and T-branch adapter table, fuse location tables, precautions when cleaning and replacing KDPF, prepare short circuit electrical connector, failure code table), troubleshooting by failure code (hundreds of failure codes from 1500L0 through CA4952, D130KA through F318KY with detailed diagnostic procedures), troubleshooting of electrical system (E-mode, E-1 through E-42 covering engine start, preheating, monitor display, gauges, alarms, wipers, washers, lamps, and KOMTRAX), troubleshooting for hydraulic and mechanical systems (H-mode, H-1 through H-22 covering power, travel, steering, brake, oil overheat, noise, fan speed), troubleshooting of engine (S-mode, S-1 through S-26 covering cranking, exhaust smoke, startability, pick-up, stopping, rough running, power loss, KDPF clogging, oil consumption, fuel consumption, coolant issues, oil pressure, fuel mixing, water mixing, overheat, noise, vibration, air bleeding, active regeneration, DEF consumption, unusual smell, foreign materials in DEF)
• 50 Disassembly and Assembly – Precautions before work, abbreviation list, related information, how to read the manual, coating materials list, special tool list, sketches of special tools, engine and cooling system (remove and install supply pump, injector, cylinder head, EGR valve, EGR cooler, starter, alternator belt, automatic tensioner, expansion tank, radiator, hydraulic oil cooler, aftercooler, power train oil cooler, cooling fan drive, cooling fan motor, engine assembly, engine front oil seal, engine rear oil seal, engine hood, fuel tank, DEF tank, DEF tank sensor flange, DEF tank sensor, DEF tank strainer, KDPF, disassemble and assemble KDPF, remove and install SCR assembly, KDPF and SCR assembly, KCCV assembly, DEF mixing tube, DEF injector, DEF pump, DEF hose, air cleaner, air conditioner compressor, air conditioner condenser), power train (remove and install damper, power train unit, disconnect and connect power train unit, disassemble and assemble PTO, torque converter, transmission, HSS assembly, remove and install HSS motor, final drive, disassemble and assemble final drive), undercarriage and frame (remove and install track frame, idler, disassemble and assemble idler, remove and install recoil spring, disassemble and assemble recoil spring, remove and install track roller, disassemble and assemble track roller, remove and install carrier roller, disassemble and assemble carrier roller, remove and install pivot shaft, separate and connect track assembly, separate and connect PLUS type track assembly, disassemble and assemble track assembly generally, disassemble and assemble PLUS type track assembly generally, disassemble and assemble one track link assembly in field, disassemble and assemble one track link assembly in field PLUS type, remove and install equalizer bar, disassemble and assemble equalizer bar bushing), hydraulic system (remove and install hydraulic tank, HSS pump and cooling fan pump, power train pump and steering lubrication pump, scavenging pump, 5 spool control valve, 4 spool control valve, disassemble and assemble blade PPC valve, ripper PPC valve), work equipment (remove and install straight tilt power pitch dozer blade, power angle power tilt dozer blade, ripper assembly, disassemble and assemble work equipment cylinder), CAB related parts (remove and install operator cab, operator cab glass, air conditioner unit, operator seat, seat belt), electrical system (remove and install engine controller, power train controller, machine monitor, mass air flow and temperature sensor, KCCV crankcase pressure sensor, SCR temperature sensor, rearview camera, KOMTRAX terminal, Gateway Function Controller, communication terminal)
• 60 Maintenance Standard – Engine and cooling system (engine mount, damper, cooling system, cooling fan pump, cooling fan motor), power train (universal joint, power train mount, torque converter and PTO, lockup clutch ECMV, transmission, transmission control valve, forward and reverse clutch ECMV and gear speed clutch ECMV, main relief valve and torque converter relief valve, transmission lubrication relief valve, bevel gear shaft, HSS, brake, brake valve, final drive, sprocket for conventional type track shoes, sprocket tooth profile full-scale drawing for conventional type track shoes, sprocket for PLUS type track shoes, sprocket tooth profile full-scale drawing for PLUS type track shoes), undercarriage and frame (main frame, suspension, track frame and idler cushion, idler, track roller for conventional type track shoes, track roller for PLUS type track shoes single flange, track roller for PLUS type track shoes double flange, carrier roller for conventional type track shoes, carrier roller for PLUS type track shoes, conventional type track shoes, PLUS type track shoes, single shoes, swamp shoes), hydraulic system (hydraulic tank, scavenging pump, steering lubrication pump and power train pump, work equipment and HSS pump, PC-EPC valve, HSS motor, control valve, blade PPC valve, ripper PPC valve, angle control EPC valve, quick drop valve, work equipment lock solenoid valve for tilt dozer and angle dozer series, work equipment lock solenoid valve for power tilt pitch dozer series, work equipment lock solenoid valve for power angle power tilt dozer series), work equipment (front work equipment for tilt dozer and power tilt pitch dozer series, front work equipment for power angle power tilt dozer series, front work equipment for angle dozer series, cutting edge and end bit, blade lift cylinder, blade tilt cylinder, blade pitch cylinder, blade angle cylinder, fixed multi-shank ripper, ripper lift cylinder), CAB related parts (CAB mount)
• 80 Appendix – Precautions before work, abbreviation list, air conditioner system (precautions for refrigerant, air conditioner component, specifications, structure and function of refrigeration cycle, outline of refrigeration cycle, component parts, air conditioner unit, air conditioner controller, compressor, condenser, receiver drier, air conditioner related sensors, explanation of procedure for test and troubleshooting, circuit diagram and configuration of connector pins, system diagram, input and output signals of air conditioner controller, locations of air conditioner parts and layout of connectors, examine air leakage, self-diagnosis function, open electrical system abnormality record screen, examine vent changeover, examine fresh/recirc air changeover, examine sunlight sensor, examine refrigerant pressure switch, examine relay, air conditioner troubleshooting charts, information shown in troubleshooting table, failure codes, A-1 through A-4 troubleshooting, troubleshooting by gauge pressure, connect service tool, precautions for disconnection and connection of air conditioner piping, handle compressor oil)
• 90 Circuit Diagrams – Hydraulic circuit diagram (symbols used, for straight tilt and SIGMADOZER, for straight tilt power pitch dozer, for power angle power tilt dozer, and 3D machine control spec versions), electrical circuit diagram (symbols used, electrical circuit diagram for machine with KOMTRAX terminal 1/16 through 16/16, electrical circuit diagram for machine with Gateway Function Controller 1/18 through 18/18)

This Komatsu D65EX-18 D65PX-18 D65WX-18 shop manual is not a generic overview. It is a complete technical reference that walks a technician through every procedure, specification, and diagnostic path for these bulldozer models. The document includes detailed electrical and hydraulic circuit diagrams that are essential for tracing faults, full disassembly and assembly procedures with tightening torques and special tool references, and a comprehensive failure code table with troubleshooting steps for every code the machine can display. The maintenance standard section provides the wear limits, clearances, and adjustment values needed to judge whether components can be reused or must be replaced.

What This Manual Enables You to Do

With this Komatsu D65 bulldozer shop manual, you can confidently perform engine overhauls on the SAA6D114E-6, diagnose and repair the Urea SCR system including DEF pump, DEF injector, and SCR assembly, troubleshoot every failure code the machine monitor can display, service the power train including torque converter, transmission, HSS unit, and final drives, rebuild undercarriage components, test and adjust hydraulic pressures and flows, and follow structured diagnostic procedures for both electrical and mechanical systems. The manual also covers the KOMTRAX system, machine monitor operation, and air conditioner service in the appendix.

IMAGES PREVIEW

Correct procedures and accurate specifications matter. Using the wrong torque, clearance, or diagnostic path can damage components, shorten service life, or create safety hazards. This manual gives you the exact values and steps that Komatsu specifies for these machines, so you can work efficiently and avoid guesswork. Delivered as an instant PDF download, the manual is available on any device, requires no shipping, and can be printed for use in the workshop. Whether you are a professional technician, a fleet maintenance manager, or an owner-operator who services your own machine, this Komatsu D65EX-18 D65PX-18 D65WX-18 shop manual provides the information you need to keep the machine running correctly.