Komatsu D65EX-80001 Install guide

BULLDOZER
SEN04887-14
D65EX
-16
D65PX
-16
D65WX
-16
SERIAL NUMBERS
D65EX- 80001
D65PX- 80001
D65WX-80001
and up

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D65EX, PX, WX-16 00-100 1
SEN04931-14
BULLDOZER
D65EX-16
D65PX-16
D65WX-16
Machine model Serial number
D65EX-16 80001 and up
D65PX-16 80001 and up
D65WX-16 80001 and up
00 Index and foreword 00
100 Index
Composition of shop manual ..................................................................................................................................2
Table of contents .....................................................................................................................................................4
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SEN04931-14
00-100 2 D65EX, PX, WX-16
Composition of shop manual
100 Index
Composition of shop manual 1
The contents of this shop manual are shown together with Form No. in a list.
Note 1: Always keep the latest version of this manual in accordance with this list and utilize accordingly.
The marks shown to the right of Form No. denote the following:
Q: New issue (to be filed additionally) q: Revision (to be replaced for each Form No.)
Note 2: This shop manual can be supplied for each Form No.
Note 3: To file this shop manual in the special binder for management, handle it as follows:
• Place a divider on the top of each section in the file after matching the Tab No. with No. indicated
next to each Section Name shown in the table below:
• File overview and other materials in sections in the order shown below and utilize them accord-
ingly.
Section Title Form Number
Shop Manual, contents binder, binder label and tabs .....................................................................SEN04887-14
00 Index and foreword ....................................................................................................................SEN04923-14
100 Index..................................................................................................................................SEN04931-14
q
200 Foreword and general information.....................................................................................SEN04932-01
01 General ......................................................................................................................................SEN04924-03
100 Specification and technical data.........................................................................................SEN04933-03
10 Structure, function and maintenance standard...........................................................................SEN04925-07
100 Engine and cooling system................................................................................................SEN04963-01
201 Power train, Part 1.............................................................................................................SEN04964-01
202 Power train, Part 2.............................................................................................................SEN04965-01
300 Undercarriage and frame...................................................................................................SEN04966-04
q
401 Hydraulic system, Part 1....................................................................................................SEN04967-00
402 Hydraulic system, Part 2....................................................................................................SEN04968-01
403 Hydraulic system, Part 3....................................................................................................SEN04969-00
500 Work equipment.................................................................................................................SEN04970-02
600 Cab and its attachments ....................................................................................................SEN04971-02
700 Electrical system................................................................................................................SEN04972-02
20 Standard value table...................................................................................................................SEN04926-03
100 Standard service value table.............................................................................................. SEN05118-03
30 Testing and adjusting .................................................................................................................SEN04927-05
101 Testing and adjusting, Part 1..............................................................................................SEN05119-02
102 Testing and adjusting, Part 2..............................................................................................SEN05120-03
103 Testing and adjusting, Part 3..............................................................................................SEN05121-02
104 Testing and adjusting, Part 4..............................................................................................SEN05122-01
40 Troubleshooting..........................................................................................................................SEN04928-03
100 Failure code table and fuse locations ................................................................................SEN05029-01
200 General information on troubleshooting.............................................................................SEN05030-01
301 Troubleshooting by failure code (Display of code), Part 1 .................................................SEN05031-00
302 Troubleshooting by failure code (Display of code), Part 2 .................................................SEN05032-01
303 Troubleshooting by failure code (Display of code), Part 3 .................................................SEN05033-01
304 Troubleshooting by failure code (Display of code), Part 4 .................................................SEN05034-01
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SEN04931-14
D65EX, PX, WX-16 00-100 3
Composition of shop manual
100 Index
305 Troubleshooting by failure code (Display of code), Part 5..................................................SEN05035-01
306 Troubleshooting by failure code (Display of code), Part 6..................................................SEN05036-01
400 Troubleshooting of electrical system (E-mode)..................................................................SEN05037-01
500 Troubleshooting of hydraulic and mechanical system (H-mode)........................................SEN05038-00
600 Troubleshooting of engine (S-mode)..................................................................................SEN05039-00
50 Disassembly and assembly........................................................................................................SEN04929-06
100 General information on disassembly and assembly...........................................................SEN05110-01
200 Engine and cooling system ................................................................................................SEN05111-01
300 Power train.........................................................................................................................SEN05112-02
400 Undercarriage and frame ...................................................................................................SEN05113-04
q
500 Hydraulic system................................................................................................................SEN05114-00
600 Work equipment .................................................................................................................SEN05115-01
q
700 Cab and its attachments.....................................................................................................SEN05116-01
800 Electrical system ................................................................................................................SEN05117-00
80 Appendix.....................................................................................................................................SEN05040-00
100 Air conditioner ....................................................................................................................SEN05041-00
90 Diagrams and drawings..............................................................................................................SEN04930-04
100 Hydraulic diagrams and drawings......................................................................................SEN04934-02
200 Electrical diagrams and drawings.......................................................................................SEN04935-03
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SEN04931-14
00-100 4 D65EX, PX, WX-16
Table of contents
100 Index
Table of contents 1
00 Index and foreword
100 Index..........................................................................................................................................SEN04931-14
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.................................................................................................SEN04933-03
Specification dimension drawing................................................................................................................... 2
Specifications................................................................................................................................................ 8
Weight table.................................................................................................................................................. 20
Table of fuel, coolant and lubricants.............................................................................................................. 24
10 Structure, function and maintenance standard
100 Engine and cooling system........................................................................................................SEN04963-01
Engine mount................................................................................................................................................ 3
Cooling system.............................................................................................................................................. 4
Cooling fan pump.......................................................................................................................................... 6
Cooling fan motor.......................................................................................................................................... 20
Coolant preheater (subextremely cold weather spec.).................................................................................. 26
201 Power train, Part 1.....................................................................................................................SEN04964-01
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
Main relief and torque converter relief valve (subextremely cold weather spec.) ......................................... 56
Transmission lubrication relief valve ............................................................................................................. 58
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...........................................................................................................SEN04966-04
Main frame.................................................................................................................................................... 2
Suspension ................................................................................................................................................... 4
Track frame and idler cushion....................................................................................................................... 14
Idler............................................................................................................................................................... 18
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SEN04931-14
D65EX, PX, WX-16 00-100 5
Table of contents
100 Index
Idler (Without idler support automatic thrust adjustment).............................................................................. 20
Track roller..................................................................................................................................................... 22
Carrier roller................................................................................................................................................... 26
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 ........................................................................................................................SEN04970-02
Blade ............................................................................................................................................................. 2
Cutting edge and end bit ............................................................................................................................... 10
Ripper (Multi shank) ...................................................................................................................................... 12
Ripper (Single shank).................................................................................................................................... 13
Hydraulic cylinder .......................................................................................................................................... 14
Piston valve................................................................................................................................................... 18
600 Cab and its attachments............................................................................................................SEN04971-02
Cab mount..................................................................................................................................................... 2
Cab................................................................................................................................................................ 3
Subextremely cold spec. cab (subextremely cold weather spec.)................................................................. 4
FRP canopy mount........................................................................................................................................ 5
FRP canopy................................................................................................................................................... 6
700 Electrical system .......................................................................................................................SEN04972-02
Monitor system.............................................................................................................................................. 2
Engine control system................................................................................................................................... 18
Cooling system control system...................................................................................................................... 21
Electronic steering control system................................................................................................................. 23
KOMTRAX system ........................................................................................................................................ 26
KOMTRAX terminal (for GPRS).................................................................................................................... 28
System components...................................................................................................................................... 29
Sensor........................................................................................................................................................... 37
20 Standard value table
100 Standard service value table ..................................................................................................... SEN05118-03
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
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SEN04931-14
00-100 6 D65EX, PX, WX-16
Table of contents
100 Index
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
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......................................................................................................SEN05120-03
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
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SEN04931-14
D65EX, PX, WX-16 00-100 7
Table of contents
100 Index
40 Troubleshooting
100 Failure code table and fuse locations........................................................................................SEN05029-01
Failure codes table ........................................................................................................................................ 2
Fuse locations ............................................................................................................................................... 7
200 General information on troubleshooting....................................................................................SEN05030-01
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
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SEN04931-14
00-100 8 D65EX, PX, WX-16
Table of contents
100 Index
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
303Troubleshooting by failure code (Display of code), Part 3.............................................................SEN05033-01
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 .........................................................SEN05035-01
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection................................................................... 4
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