KOMATSU D65EX -15E0 D65PX -15E0 D65WX -15E0 BULLDOZER SHOP MANUAL SEN00046-11 – PDF DOWNLOAD
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KOMATSU D65EX -15E0 D65PX -15E0 D65WX -15E0 BULLDOZER SHOP MANUAL SEN00046-11 – PDF DOWNLOAD
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KOMATSU D65EX -15E0 D65PX -15E0 D65WX -15E0 BULLDOZER SHOP MANUAL SEN00046-11 – PDF DOWNLOAD
Cover........................................................................................................................................ 1 00 Index and foreword........................................................................................................................ 0 Index.................................................................................................................................... 3 Composition of shop manual........................................................................................................... 4 Table of contents.................................................................................................................... 6 Foreword and general information......................................................................................................... 17 Safety notice........................................................................................................................ 18 How to read the shop manual.......................................................................................................... 23 Explanation of terms for maintenance standard........................................................................................ 25 Handling of electric equipment and hydraulic component............................................................................... 27 Handling of connectors newly used for engines........................................................................................ 36 How to read electric wire code....................................................................................................... 39 Precautions when carrying out operation.............................................................................................. 42 Method of disassembling and connecting push-pull type coupler........................................................................ 45 Standard tightening torque table..................................................................................................... 48 Conversion table..................................................................................................................... 52 01 Specification............................................................................................................................. 0 Specification and technical data......................................................................................................... 59 Specification dimensions............................................................................................................. 60 Specifications....................................................................................................................... 61 Weight table......................................................................................................................... 66 Table of fuel, coolant and lubricants................................................................................................ 68 10 Structure, function and maintenance standard.............................................................................................. 0 Engine and cooling system................................................................................................................ 71 Cooling system....................................................................................................................... 72 Cooling fan pump..................................................................................................................... 74 Cooling fan motor.................................................................................................................... 82 Power train, Part 1...................................................................................................................... 89 Power train.......................................................................................................................... 90 HSS system........................................................................................................................... 92 General view of power train unit..................................................................................................... 94 Power train hydraulic piping drawing................................................................................................. 96 Transmission, steering and brake control............................................................................................. 98 Damper and universal joint........................................................................................................... 100 Torque converter and PTO............................................................................................................. 103 Transmission......................................................................................................................... 108 Transmission clutch ECMV............................................................................................................. 124 Main relief valve and torque converter relief valve.................................................................................. 130 Lubrication relief valve............................................................................................................. 132 Power train, Part 2...................................................................................................................... 135 Bevel gear shaft, HSS and brake...................................................................................................... 136 Brake valve.......................................................................................................................... 158 Final drive.......................................................................................................................... 164 Undercarriage and frame.................................................................................................................. 171 Main frame........................................................................................................................... 172 Suspension........................................................................................................................... 174 Track frame and idler cushion........................................................................................................ 180 Idler................................................................................................................................ 184 Track roller......................................................................................................................... 186 Carrier roller....................................................................................................................... 190 Sprocket............................................................................................................................. 192 Track shoe........................................................................................................................... 196 Hydraulic system, Part 1................................................................................................................. 203 Work equipment hydraulic piping diagram.............................................................................................. 204 Work equipment control............................................................................................................... 206 Hydraulic tank and filter............................................................................................................ 208 Scavenging pump...................................................................................................................... 210 Power train and steering lubrication pump............................................................................................ 211 HSS pump............................................................................................................................. 212 HSS motor............................................................................................................................ 230 Hydraulic system, Part 2................................................................................................................. 239 Control valve........................................................................................................................ 240 Self pressure reducing valve......................................................................................................... 274 Hydraulic system, Part 3................................................................................................................. 283 PPC valve (blade lift, blade tilt)................................................................................................... 284 PPC valve (ripper)................................................................................................................... 290 Electric lever (steering)............................................................................................................ 294 Quick drop valve..................................................................................................................... 298 PPC lock valve....................................................................................................................... 300 Accumulator.......................................................................................................................... 301 Work equipment........................................................................................................................... 303 Blade................................................................................................................................ 304 Cutting edge and end bit............................................................................................................. 308 Ripper............................................................................................................................... 309 Hydraulic cylinder................................................................................................................... 310 Piston valve......................................................................................................................... 313 Cab and its attachments.................................................................................................................. 315 Cab mount............................................................................................................................ 316 Cab.................................................................................................................................. 317 Air conditioner...................................................................................................................... 319 Electrical system........................................................................................................................ 321 Monitor system....................................................................................................................... 322 Monitor panel........................................................................................................................ 324 Engine control....................................................................................................................... 333 Engine control system................................................................................................................ 334 Cooling system control system........................................................................................................ 336 System components.................................................................................................................... 338 Palm command control system.......................................................................................................... 346 KOMTRAX system....................................................................................................................... 348 Sensor............................................................................................................................... 350 20 Standard service value table.............................................................................................................. 0 Standard service value table............................................................................................................. 355 Standard service value table for engine.............................................................................................. 356 Standard service value table for chassis............................................................................................. 358 30 Testing and adjusting..................................................................................................................... 0 Testing and adjusting, Part 1............................................................................................................ 371 Tools for testing, adjusting, and troubleshooting.................................................................................... 373 Measuring engine speed............................................................................................................... 376 Measuring intake air pressure (boost pressure)....................................................................................... 378 Measuring exhaust temperature........................................................................................................ 380 Measuring exhaust gas color.......................................................................................................... 382 Adjusting valve clearance............................................................................................................ 383 Measuring compression pressure....................................................................................................... 386 Measuring blow-by pressure........................................................................................................... 390 Measuring engine oil pressure........................................................................................................ 391 Handling of fuel system devices...................................................................................................... 392 Releasing residual pressure from fuel system......................................................................................... 392 Testing fuel pressure................................................................................................................ 393 Testing fuel return and leak amount.................................................................................................. 398 Bleeding air from fuel circuit....................................................................................................... 400 Testing fuel circuit for leakage..................................................................................................... 401 Handling of reduced cylinder mode operation.......................................................................................... 402 Testing and adjusting air conditioner compressor belt tension........................................................................ 403 Adjusting fuel control dial and decelerator pedal.................................................................................... 404 Measuring power train oil pressure................................................................................................... 406 Adjusting transmission speed sensor (replacement procedure).......................................................................... 410 Simple method to test brake performance.............................................................................................. 411 Adjusting brake pedal................................................................................................................ 412 Adjusting parking brake lever........................................................................................................ 414 Emergency escape method when power train has trouble................................................................................. 415 Adjusting clearance of idler......................................................................................................... 418 Inspecting wear of sprocket.......................................................................................................... 419 Testing and adjusting track shoe tension............................................................................................. 419 Testing and adjusting work equipment and HSS oil pressure............................................................................ 420 Testing control circuit basic pressure............................................................................................... 423 Measuring PPC valve output pressure.................................................................................................. 424 Adjusting work equipment PPC valve play.............................................................................................. 426 Measuring internal leakage of work equipment cylinder................................................................................ 428 Bleeding air from work equipment cylinder............................................................................................ 428 Releasing residual pressure in work equipment cylinder............................................................................... 429 Checking parts which caused hydraulic drift of blade or ripper....................................................................... 430 Adjusting work equipment lock lever.................................................................................................. 431 Measuring fan motor speed............................................................................................................ 432 Measuring fan pump circuit pressure.................................................................................................. 433 Bleeding air from fan pump........................................................................................................... 434 Adjusting straight tiltdozer......................................................................................................... 435 Testing and adjusting operator cab................................................................................................... 437 Testing and adjusting, Part 2............................................................................................................ 443 Special functions of monitor panel (EMMS)............................................................................................ 444 Testing and adjusting, Part 3............................................................................................................ 487 Handling of voltage circuit of engine controller..................................................................................... 488 Adjustment method when controller has been replaced.................................................................................. 488 Preparation work for troubleshooting for electric system............................................................................. 490 Inspection procedure of diode........................................................................................................ 495 Pm-Clinic service.................................................................................................................... 496 How to start operation of KOMTRAX terminal........................................................................................... 506 Lamp display of KOMTRAX terminal..................................................................................................... 510 40 Troubleshooting........................................................................................................................... 0 General information on troubleshooting................................................................................................... 515 Points to remember when troubleshooting.............................................................................................. 516 How to proceed troubleshooting....................................................................................................... 517 Checks before troubleshooting........................................................................................................ 518 Classification and procedures of troubleshooting..................................................................................... 519 How to distinguish wire code......................................................................................................... 522 Connection table for connector pin numbers........................................................................................... 526 T- branch box and T- branch adapter table............................................................................................ 562 Troubleshooting by failure code (Display of code), Part 1................................................................................ 567 Failure code table................................................................................................................... 569 Before troubleshooting by failure codes.............................................................................................. 576 Contents of troubleshooting table.................................................................................................... 578 Failure code [1500L0] Transmission clutch: Dual engagement........................................................................... 580 Failure code [15SAL1] Forward clutch: Fill signal is ON when command current is OFF.................................................. 582 Failure code [15SALH] Forward clutch: Fill signal is OFF when command current is ON.................................................. 584 Failure code [15SBL1] Reverse clutch: Fill signal is ON when command current is OFF.................................................. 586 Failure code [15SBLH] Reverse clutch: Fill signal is OFF when command current is ON.................................................. 588 Failure code [15SEL1] 1st clutch: Fill signal is ON when command current is OFF...................................................... 590 Failure code [15SELH] 1st clutch: Fill signal is OFF when command current is ON...................................................... 591 Failure code [15SFL1] 2nd clutch: Fill signal is ON when command current is OFF...................................................... 592 Failure code [15SFLH] 2nd clutch: Fill signal is OFF when command current is ON...................................................... 594 Failure code [15SGL1] 3rd clutch: Fill signal is ON when command current is OFF...................................................... 596 Failure code [15SGLH] 3rd clutch: Fill signal is OFF when command current is ON...................................................... 598 Failure code [AB00MA] Alternator: Malfunction........................................................................................ 600 Failure code [B@BAZG] Engine oil: Oil pressure too low............................................................................... 600 Failure code [B@BCNS] Radiator coolant: Overheat..................................................................................... 601 Failure code [B@CENS] Power train oil: Overheat...................................................................................... 601 Failure code [B@HANS] Hydraulic oil: Overheat........................................................................................ 602 Failure code [CA111] Engine controller: Abnormality in controller.................................................................... 603 Failure code [CA115] Abnormal engine Ne and Bkup speed sensors:Abnormal speed sensor signal.......................................... 603 Failure code [CA122] Charge pressure sensor too high:Excessively high voltage detected............................................... 604 Failure code [CA123] Charge pressure sensor too low: Excessively low voltage detected................................................ 606 Failure code [CA131] Decelerator pedal sensor too high:Excessively high voltage detected............................................. 608 Failure code [CA132] Decelerator pedal sensor too low: Excessively low voltage detected.............................................. 610 Failure code [CA144] Coolant temperature sensor too high:Excessively high voltage detected........................................... 612 Failure code [CA145] Coolant temperature sensor too low:Excessively low voltage detected............................................. 614 Failure code [CA153] Charge temperature sensor too high:Excessively high voltage detected............................................ 616 Failure code [CA154] Charge temperature sensor too low:Excessively low voltage detected.............................................. 618 Failure code [CA155] Charge temperature too high and engine speed derated:Exceeded upper control limit of temperature................ 620 Failure code [CA187] Sensor power source 2 too low: Excessively low voltage detected................................................. 622 Failure code [CA221] Atmospheric pressure sensor too high:Excessively high voltage detected.......................................... 624 Failure code [CA222] Atmospheric pressure sensor too low:Excessively low voltage detected............................................ 626 Failure code [CA227] Sensor power source 2 too high: Excessively high voltage detected............................................... 628 Failure code [CA234] Engine over speed: Excessively high speed....................................................................... 630 Failure code [CA238] Abnormal power source for Ne speed sensor:Excessively low voltage detected...................................... 631 Failure code [CA271] IMV/PCV1 short circuit: Short circuit........................................................................... 632 Failure code [CA272] IMV/PCV1 disconnection: Disconnection........................................................................... 634 Failure code [CA281] Abnormal supply pump pressure balance:Abnormal pressure feed of fuel............................................ 636 Troubleshooting by failure code (Display of code), Part 2................................................................................ 639 Failure code [CA322] Injector No. 1 system disconnection or short circuit:disconnection, short circuit............................... 642 Failure code [CA323] Injector No. 5 system disconnection or short circuit:disconnection, short circuit............................... 644 Failure code [CA324] Injector No. 3 system disconnection or short circuit:disconnection, short circuit............................... 646 Failure code [CA325] Injector No. 6 system disconnection or short circuit:disconnection, short circuit............................... 648 Failure code [CA331] Injector No. 2 system disconnection or short circuit:disconnection, short circuit............................... 650 Failure code [CA332] Injector No. 4 system disconnection or short circuit:disconnection, short circuit............................... 652 Failure code [CA342] Engine controller data matching error: matching error........................................................... 654 Failure code [CA352] Sensor power source 1 too low: Excessively low voltage detected................................................. 656 Failure code [CA386] Sensor power source 1 too high: Excessively high voltage detected............................................... 658 Failure code [CA428] Water detection sensor too high: Excessively high voltage detected.............................................. 660 Failure code [CA429] Water detection sensor too low: Excessively low voltage detected................................................ 662 Failure code [CA435] Abnormal engine oil pressure switch: Abnormal signal circuit.................................................... 664 Failure code [CA441] Power source voltage too low: Excessively low voltage detected.................................................. 666 Failure code [CA442] Power source voltage too high: Excessively high voltage has occurred in the controller power source circuit..... 668 Failure code [CA449] Common rail pressure too high (2):Excessively high pressure trouble occurred.................................... 670 Failure code [CA451] Common rail pressure sensor too high:Excessively high voltage detected.......................................... 674 Failure code [CA452] Common rail pressure sensor too low:Excessively low voltage detected............................................ 676 Failure code [CA488] Charge temperature too high and torque derated:Exceeded upper control limit of temperature...................... 678 Failure code [CA553] Common rail pressure too high (1):Excessively high pressure detected............................................ 679 Failure code [CA559] Loss of pressure feed from supply pump (1):Loss of pressure feed detected....................................... 680 Failure code [CA689] Abnormal engine Ne speed sensor: Abnormal signal................................................................ 682 Failure code [CA731] Abnormal engine Bkup speed sensor phase: Abnormal phase......................................................... 684 Failure code [CA757] Loss of all engine controller data: Loss of all data............................................................ 686 Failure code [CA778] Abnormal engine Bkup speed sensor: Abnormal Bkup signal......................................................... 688 Failure code [CA1633] Abnormal KOMNET: Abnormal communication........................................................................ 690 Failure code [CA2185] Decelerator pedal sensor power source too high:Excessively high voltage detected............................... 692 Failure code [CA2186] Decelerator pedal sensor power source too low:Excessively low voltage detected................................. 693 Failure code [CA2249] Loss of pressure feed from supply pump (2):Loss of pressure feed detected...................................... 694 Failure code [CA2265] Electric lift pump disconnection: Disconnection................................................................ 696 Failure code [CA2266] Electric lift pump short circuit: Short circuit................................................................ 698 Failure code [CA2311] Abnormal IMV solenoid: Abnormal resistance..................................................................... 700 Failure code [CA2555] Air intake heater relay disconnection: Disconnection........................................................... 702 Failure code [CA2556] Air intake heater relay short circuit: Short circuit........................................................... 704 Troubleshooting by failure code (Display of code), Part 3................................................................................ 707 Failure code [D110KA] Battery relay: Short circuit................................................................................... 710 Failure code [D110KB] Battery relay: Disconnection................................................................................... 712 Failure code [D130KA] Neutral safety relay: Disconnection............................................................................ 714 Failure code [D130KB] Neutral safety relay: Short circuit............................................................................ 716 Failure code [D161KA] Back-up alarm relay: Disconnection............................................................................. 718 Failure code [D161KB] Back-up alarm relay: Short circuit............................................................................. 720 Failure code [DAFRKR] Monitor panel CAN communication: Defective communication....................................................... 722 Failure code [DAQ0KT] [DB30KT] Steering and transmission controller:Abnormality in controller........................................ 724 Failure code [DAQ1KK] [DB31KK] Main power source of steering and transmission controller: Power source voltage drop and input........ 726 Failure code [DAQ2KK] [DB32KK] Load power source of steering and transmission controller: Power source voltage drop and input........ 728 Failure code [DAQ5KK] [DB35KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input..... 730 Failure code [DAQ6KK] [DB36KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input.... 732 Failure code [DAQ9KQ] [DB39KQ] Steering and transmission controller model selection: Inconsistency in model select signal............ 734 Failure code [DB2RKR] Steering and transmission controller CAN communication: Defective communication................................ 736 Failure code [DB30KT] [DAQ0KT] Steering and transmission controller: Abnormality in controller....................................... 738 Failure code [DB31KK] [DAQ1KK] Main power source of steering and transmission controller: Power source voltage drop and input........ 738 Failure code [DAB32KK] [DAQ2KK] Load power source of steering and transmission controller: Power source voltage drop and input....... 738 Failure code [DB35KK] [DAQ5KK] Steering and transmission controller sensor 5 V power source: Power source voltage drop and input..... 738 Failure code [DB36KK] [DAQ6KK] Steering and transmission controller sensor 24 V power source: Power source voltage drop and input.... 738 Failure code [DB39KQ] [DAQ9KQ] Steering and transmission controller model selection:Inconsistency in model select signal............. 738 Failure code [DD12KA] Shift up switch: Disconnection................................................................................. 740 Failure code [DD12KB] Shift up switch: Short circuit................................................................................. 742 Failure code [DD13KA] Shift down switch: Disconnection............................................................................... 744 Failure code [DD13KB] Shift down switch: Short circuit............................................................................... 746 Failure code [DD14KA] [DDQ2KA] Parking brake lever switch: Disconnection............................................................. 748 Failure code [DD14KB] [DDQ2KB] Parking brake lever switch: Short circuit............................................................. 750 Failure code [DDN7KA] Pitch control switch: Disconnection............................................................................ 752 Failure code [DDN7KB] Pitch control switch: Short circuit............................................................................ 754 Failure code [DDQ2KA] [DD14KA] Parking brake lever switch: Disconnection............................................................. 756 Failure code [DDQ2KB] [DD14KB] Parking brake lever switch: Short circuit............................................................. 756 Failure code [DGS1KX] Hydraulic oil temperature sensor:Input signal is out of normal range........................................... 758 Failure code [DGT1KA] Power train oil temperature sensor: Disconnection.............................................................. 760 Failure code [DGT1KX] Power train oil temperature sensor: Input signal is out of normal range........................................ 761 Failure code [DK10KA] Fuel dial: Disconnection....................................................................................... 762 Failure code [DK10KB] Fuel dial: Short circuit....................................................................................... 764 Failure code [DK30KA] Steering potentiometer (1): Disconnection...................................................................... 766 Failure code [DK30KB] Steering potentiometer (1): Short circuit...................................................................... 768 Failure code [DK30KX] Steering potentiometer: Input signal is out of normal range.................................................... 770 Failure code [DK30KZ] Steering potentiometer: Disconnection or short circuit (Double failure)........................................ 771 Failure code [DK30L8] Steering potentiometer: Inconsistent analog signal............................................................. 771 Failure code [DK31KA] Steering potentiometer (2): Disconnection...................................................................... 772 Failure code [DK31KB] Steering potentiometer (2): Short circuit...................................................................... 774 Failure code [DK40KA] Brake potentiometer: Disconnection............................................................................. 776 Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................. 777 Failure code [DK55KX] Forward-reverse potentiometer: Input signal is out of normal range............................................. 778 Failure code [DK55KZ] Forward-reverse potentiometer:Disconnection or short circuit (Double failure).................................. 779 Failure code [DK55L8] Forward-reverse potentiometer: Inconsistent analog signal...................................................... 780 Failure code [DK56KA] Forward-reverse potentiometer (1): Short circuit............................................................... 782 Failure code [DK56KB] Forward-reverse potentiometer (1): Disconnection............................................................... 784 Failure code [DK57KA] Forward-reverse potentiometer (2): Disconnection............................................................... 786 Failure code [DK57KB] Forward-reverse potentiometer (2): Short circuit............................................................... 788 Troubleshooting by failure code (Display of code), Part 4................................................................................ 791 Failure code [DKH1KA] [DKH1KX] Pitch angle sensor: Short circuit..................................................................... 793 Failure code [DKH1KX], [DKH1KA] or [DKH1KB] Pitch angle sensor: Input signal out of range............................................ 795 Failure code [DLT3KA] Transmission output speed sensor: Disconnection................................................................ 796 Failure code [DLT3KB] Transmission output speed sensor: Short circuit................................................................ 797 Failure code [DV00KB] Alarm buzzer: Short circuit.................................................................................... 798 Failure code [DW5AKA] Pitch control solenoid: Disconnection.......................................................................... 799 Failure code [DW5AKB] Pitch control solenoid: Short circuit.......................................................................... 800 Failure code [DW5AKY] Pitch control solenoid: Short circuit to power source line..................................................... 801 Failure code [DW7BKA] Fan reverse solenoid: Disconnection............................................................................ 802 Failure code [DW7BKB] Fan reverse solenoid: Short circuit............................................................................ 803 Failure code [DWN1KA] HSS EPC solenoid right: Disconnection.......................................................................... 804 Failure code [DWN1KB] HSS EPC solenoid right: Short circuit.......................................................................... 805 Failure code [DWN1KY] HSS EPC solenoid right: Short circuit to power source line..................................................... 806 Failure code [DWN2KA] HSS EPC solenoid left: Disconnection........................................................................... 807 Failure code [DWN2KB] HSS EPC solenoid left: Short circuit........................................................................... 808 Failure code [DWN2KY] HSS EPC solenoid left: Short circuit to power source line...................................................... 809 Failure code [DWN5KA] Fan pump TVC solenoid: Disconnection........................................................................... 810 Failure code [DWN5KB] Fan pump TVC solenoid: Short circuit........................................................................... 811 Failure code [DWN5KY] Fan pump TVC solenoid: Short circuit in power source line...................................................... 812 Failure code [DXA0KA] HSS pump TVC solenoid: Disconnection........................................................................... 813 Failure code [DXA0KB] HSS pump TVC solenoid: Short circuit........................................................................... 814 Failure code [DXA0KY] HSS pump TVC solenoid: Short circuit to power source line...................................................... 815 Failure code [DXH4KA] 1st clutch ECMV: Disconnection................................................................................. 816 Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................................................. 817 Failure code [DXH4KY] 1st clutch ECMV: Short circuit to power source line............................................................ 818 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection................................................................................. 819 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit................................................................................. 820 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit to power source line............................................................ 821 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection................................................................................. 822 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................. 823 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit to power source line............................................................ 824 Failure code [DXH7KA] Reverse clutch ECMV: Disconnection............................................................................. 825 Failure code [DXH7KB] Reverse clutch ECMV: Short circuit............................................................................. 826 Failure code [DXH7KY] reverse clutch ECMV: Short circuit to power source line........................................................ 827 Failure code [DXH8KA] Forward clutch ECMV: Disconnection............................................................................. 828 Failure code [DXH8KB] Forward clutch ECMV: Short circuit............................................................................. 829 Failure code [DXH8KY] forward clutch ECMV: Short circuit to power source line........................................................ 830 Troubleshooting of electrical system (E-mode)............................................................................................ 833 Contents of troubleshooting table.................................................................................................... 837 E-1 The engine does not start (the starting motor does not turn)..................................................................... 838 E-2 The preheater does not operate................................................................................................... 842 E-3 The monitor panel does not light up at all when the starting switch is turned ON................................................. 846 E-4 When the starting switch is turned on, the monitor panel completely remains lighted and does not go out.......................... 847 E-5 While the engine is running, the battery charge level caution lamp flashes....................................................... 848 E-6 While the engine is running, the emergency warning item flashes.................................................................. 850 E-7 While the preheater is operating, the preheating pilot lamp does not light up.................................................... 854 E-8 The coolant temperature gauge does not indicate correctly........................................................................ 856 E-9 The power train oil temperature gauge does not indicate correctly................................................................ 858 E-10 Hydraulic oil temperature gauge does not indicate properly...................................................................... 861 E-11 Fuel gauge does not indicate properly........................................................................................... 864 E-12 Gear speed and engine speed are not indicated properly.......................................................................... 865 E-13 The preset mode service meter does not indicate normally........................................................................ 865 E-14 The warning lamp does not flash or does not go out.............................................................................. 865 E-15 The alarm buzzer does not sound or does not stop................................................................................ 866 E-16 Auto shift down is not possible or is not released.............................................................................. 868 E-17 The buzzer cancel switch does not work.......................................................................................... 870 E-18 The information switch does not work............................................................................................ 872 E-19 The fan cleaning does not operate or cannot be reset............................................................................ 874 E-20 The preset mode does not operate or cannot be reset............................................................................. 876 E-21 The monitor panel cannot be set in the service mode or cannot be set out of the service mode.................................... 878 E-22 The back-up alarm does not sound................................................................................................ 880 E-23 The head lamp and rear lamp do not light up..................................................................................... 882 E-24 The horn does not sound or does not stop........................................................................................ 885 E-25 Malfunction of wipers........................................................................................................... 886 E-26 Washer does not spray water..................................................................................................... 902 E-27 The air conditioner does not operate............................................................................................ 908 E-28 KOMTRAX system does not operate normally........................................................................................ 912 Troubleshooting of hydraulic and mechanical system (H-mode).............................................................................. 915 Contents of troubleshooting table.................................................................................................... 917 H-1 There is no travel power (no drawbar pull)....................................................................................... 918 H-2 Machine does not move (at 2nd or 3rd speed)...................................................................................... 919 H-3 Machine does not move at any gear speed.......................................................................................... 920 H-4 Machine travels only in one direction, forward or in reverse..................................................................... 921 H-5 When gear is shifted or travel direction is changed, large time lag is made...................................................... 922 H-6 Machine cannot be steered (Machine does not turn leftward or rightward).......................................................... 923 H-7 Steering speed or power is low................................................................................................... 923 H- 8 Brake does not work............................................................................................................. 924 H-9 Overheat of power train oil...................................................................................................... 925 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor................................................... 926 H-11 All work equipment speeds are slow.............................................................................................. 926 H-12 Work equipment does not move.................................................................................................... 927 H-13 Blade lift speed is slow or lacks power......................................................................................... 927 H-14 Blade tilt speed is slow or lacks power......................................................................................... 928 H-15 Ripper lift speed is slow or lacks power........................................................................................ 928 H-16 Excessive hydraulic drift of blade lift......................................................................................... 929 H-17 Excessive hydraulic drift of blade tilt......................................................................................... 929 H-18 Excessive hydraulic drift of ripper lift........................................................................................ 930 Troubleshooting of engine (S-mode)....................................................................................................... 933 Method of using troubleshooting charts............................................................................................... 935 S-1 Starting performance is poor..................................................................................................... 938 S-2 Engine does not start............................................................................................................ 939 S-3 Engine does not pick up smoothly................................................................................................. 942 S-4 Engine stops during operations................................................................................................... 943 S-5 Engine does not rotate smoothly.................................................................................................. 944 S-6 Engine lacks output (or lacks power)............................................................................................. 945 S-7 Exhaust smoke is black (imcomplete combustion)................................................................................... 946 S-8 Oil consumption is excessive (or exhaust smoke is blue).......................................................................... 947 S-9 Oil becomes contaminated quickly................................................................................................. 948 S-10 Fuel consumption is excessive................................................................................................... 949 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down).......................................................... 950 S-12 Oil pressure drops.............................................................................................................. 951 S-13 Oil level rises (water, fuel in oil)............................................................................................ 952 S-14 Coolant temperature becomes too high (overheating).............................................................................. 953 S-15 Abnormal noise is made.......................................................................................................... 954 S-16 Vibration is excessive.......................................................................................................... 955 50 Disassembly and assembly.................................................................................................................. 0 General information on disassembly and assembly.......................................................................................... 957 How to read this manual.............................................................................................................. 958 Coating materials list............................................................................................................... 960 Special tool list.................................................................................................................... 963 Sketches of special tools............................................................................................................ 969 Engine and cooling system, Part 1........................................................................................................ 979 Removal and installation of fuel supply pump assembly................................................................................ 980 Removal and installation of cylinder head assembly................................................................................... 984 Removal and installation of fuel injector assembly................................................................................... 999 Removal and installation of engine front oil seal....................................................................................1001 Removal and installation of engine rear oil seal.....................................................................................1004 Engine and cooling system, Part 2........................................................................................................1011 Removal and installation of engine assembly..........................................................................................1012 Removal and installation of radiator assembly........................................................................................1019 Removal and installation of air aftercooler assembly.................................................................................1023 Removal and installation of fan drive assembly.......................................................................................1024 Removal and installation of fan motor assembly.......................................................................................1025 Removal and installation of fuel tank assembly.......................................................................................1026 Removal and installation of damper assembly..........................................................................................1028 Removal and installation of engine hood assembly.....................................................................................1029 Power train, Part 1......................................................................................................................1031 Removal and installation of power train unit assembly................................................................................1032 Disconnection and connection of power train unit assembly............................................................................1035 Disassembly and assembly of PTO assembly.............................................................................................1039 Disassembly and assembly of torque converter assembly................................................................................1045 Disassembly and assembly of TORQFLOW transmission assembly...........................................................................1050 Power train, Part 2......................................................................................................................1069 Disassembly and assembly of HSS assembly.............................................................................................1070 Removal and installation of final drive assembly.....................................................................................1088 Disassembly and assembly of final drive assembly.....................................................................................1090 Undercarriage and frame, Part 1..........................................................................................................1099 Removal and installation of track frame assembly.....................................................................................1100 Removal and installation of idler assembly...........................................................................................1102 Disassembly and assembly of idler assembly...........................................................................................1103 Removal and installation of recoil spring assembly...................................................................................1107 Disassembly and assembly of recoil spring assembly...................................................................................1108 Removal and installation of track roller assembly....................................................................................1112 Disassembly and assembly of track roller assembly....................................................................................1113 Removal and installation of carrier roller assembly..................................................................................1117 Disassembly and assembly of carrier roller assembly..................................................................................1118 Undercarriage and frame, Part 2..........................................................................................................1123 Expansion and installation of track shoe assembly (Conventional type track shoe).....................................................1124 Expansion and installation of track shoe assembly (PLUS type track shoe).............................................................1127 Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)...........................................1128 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe)...................................................1141 Field disassembly and assembly of one link (Conventional type track shoe)............................................................1154 Field disassembly and assembly of one link (PLUS type track shoe)....................................................................1161 Removal and installation of pivot shaft assembly.....................................................................................1166 Removal and installation of equalizer bar assembly...................................................................................1167 Disassembly and assembly of equalizer bar side bushing...............................................................................1169 Hydraulic system.........................................................................................................................1171 Removal and installation of control valve assembly...................................................................................1172 Disassembly and assembly of control valve assembly...................................................................................1174 Removal and installation of HSS pump assembly........................................................................................1175 Removal and installation of power train and lubricating oil pump assembly............................................................1176 Removal and installation of cooling fan pump assembly................................................................................1177 Removal and installation of scavenging pump assembly.................................................................................1179 Removal and installation of HSS motor assembly.......................................................................................1180 Disassembly and assembly of hydraulic cylinder assembly..............................................................................1181 Work equipment...........................................................................................................................1189 Removal and installation of blade assembly...........................................................................................1190 Cab and its attachments..................................................................................................................1195 Removal and installation of ROPS guard...............................................................................................1196 Removal and installation of operator’s cab assembly..................................................................................1197 Removal and installation of operator’s cab glass (Stuck glass).......................................................................1203 Removal and installation of floor frame assembly.....................................................................................1211 Electrical system........................................................................................................................1219 Removal and installation of engine controller........................................................................................1220 Removal and installation of steering and transmission controller assembly............................................................1222 Removal and installation of KOMTRAX terminal.........................................................................................1223 90 Diagrams and drawings..................................................................................................................... 0 Hydraulic diagrams and drawings..........................................................................................................1225 Power train hydraulic circuit diagram................................................................................................1226 Hydraulic circuit diagram............................................................................................................1227 Electrical diagrams and drawings.........................................................................................................1230 Electrical circuit diagram...........................................................................................................1232 Connector list and stereogram........................................................................................................1240
DESCRIPTION:
KOMATSU D65EX -15E0 D65PX -15E0 D65WX -15E0 BULLDOZER SHOP MANUAL SEN00046-11 – PDF DOWNLOAD
This shop manual contains the necessary technical information for services performed in a workshop.
For ease of understanding, the manual is divided into the following sections.
00. Index and foreword
This section explains the shop manuals list, table of contents, safety, and basic information.
01. Specification
This section explains the specifications of the machine.
10. Structure, function and maintenance standard
This section explains the structure, function, and maintenance standard values of each component.
The structure and function sub-section explains the structure and function of each component. It
serves not only to give an understanding of the structure, but also serves as reference material for
troubleshooting. The maintenance standard sub-section explains the criteria and remedies for disassembly
and service.
20. Standard value table
This section explains the standard values for new machine and judgement criteria for testing,
adjusting, and troubleshooting. This standard value table is used to check the standard values in
testing and adjusting and to judge parts in troubleshooting.
30. Testing and adjusting
This section explains measuring instruments and measuring methods for testing and adjusting, and
method of adjusting each part. The standard values and judgement criteria for testing and adjusting
are explained in Testing and adjusting.
40. Troubleshooting
This section explains how to find out failed parts and how to repair them. The troubleshooting is
divided by failure modes. The “S mode” of the troubleshooting related to the engine may be also
explained in the Chassis volume and Engine volume. In this case, see the Chassis volume.
50. Disassembly and assembly
This section explains the special tools and procedures for removing, installing, disassembling, and
assembling each component, as well as precautions for them. In addition, tightening torque and
quantity and weight of coating material, oil, grease, and coolant necessary for the work are also
explained.
90. Diagrams and drawings (chassis volume)/Repair and replacement of parts (engine volume)
q Chassis volume
This section gives hydraulic circuit diagrams and electrical circuit diagrams.
q Engine volume
This section explains the method of reproducing, repairing, and replacing parts.
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