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KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SHOP MANUAL SEN04887-18 – PDF DOWNLOAD
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KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SHOP MANUAL SEN04887-18 – PDF DOWNLOAD
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KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SHOP MANUAL SEN04887-18 – PDF DOWNLOAD
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KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SHOP MANUAL SEN04887-18 – PDF DOWNLOAD
Language : English
Pages : 1620
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File Type : PDF
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KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SHOP MANUAL SEN04887-18 – PDF DOWNLOAD
Cover.......................................................................................................... 1 00 Index and foreword.......................................................................................... 3 100 Index.................................................................................................. 3 Composition of shop manual............................................................................. 4 Table of contents...................................................................................... 6 200 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 General..................................................................................................... 59 100 Specification and technical data....................................................................... 59 Specification dimension drawing........................................................................ 60 Specifications......................................................................................... 66 Weight table........................................................................................... 80 Table of fuel, coolant and lubricants.................................................................. 84 10 Structure, function and maintenance standard................................................................ 87 100 Engine and cooling system.............................................................................. 87 Engine mount........................................................................................... 89 Cooling system......................................................................................... 90 Cooling fan pump....................................................................................... 92 Cooling fan motor...................................................................................... 106 Coolant preheater (subextremely cold weather spec.).................................................... 112 201 Power train, Part 1.................................................................................... 117 Power train............................................................................................ 118 HSS system............................................................................................. 120 Overall view of power train unit....................................................................... 122 Power train hydraulic piping diagram................................................................... 126 Transmission, steering and brake control............................................................... 128 Damper................................................................................................. 130 Universal joint........................................................................................ 132 Torque converter and PTO............................................................................... 133 Transmission........................................................................................... 140 Transmission control valve............................................................................. 158 ECMV................................................................................................... 162 Main relief and torque converter relief valve.......................................................... 170 Main relief and torque converter relief valve (subextremely cold weather spec.)........................ 172 Transmission lubrication relief valve.................................................................. 174 202 Power train, Part 2.................................................................................... 177 Bevel gear shaft, HSS and brake........................................................................ 178 Brake valve............................................................................................ 200 Final drive............................................................................................ 206 Final drive (Planetary gear installed inside of sprocket type)......................................... 212 300 Undercarriage and frame................................................................................ 219 Main frame............................................................................................. 220 Suspension............................................................................................. 222 Track frame and idler cushion.......................................................................... 232 Idler.................................................................................................. 236 Idler (Without idler support automatic thrust adjustment).............................................. 238 Track roller........................................................................................... 240 Carrier roller......................................................................................... 244 Sprocket............................................................................................... 246 Track shoe............................................................................................. 250 401 Hydraulic system, Part 1............................................................................... 257 Work equipment hydraulic system layout drawing......................................................... 258 Work equipment control................................................................................. 262 Hydraulic tank and filter.............................................................................. 264 Scavenging pump........................................................................................ 266 Power train and steering lubrication pump.............................................................. 267 HSS pump............................................................................................... 268 HSS motor.............................................................................................. 287 402 Hydraulic system, Part 2............................................................................... 297 Control valve.......................................................................................... 298 CLSS................................................................................................... 307 Function and operation of each valve................................................................... 310 403 Hydraulic system, Part 3............................................................................... 335 PPC valve (blade lift, blade tilt)..................................................................... 336 PPC valve (ripper)..................................................................................... 342 Electric lever (steering).............................................................................. 346 Quick drop valve....................................................................................... 350 Work equipment lock solenoid valve..................................................................... 352 Pitch selector solenoid valve.......................................................................... 356 Hydraulic oil cooler bypass valve...................................................................... 357 Accumulator............................................................................................ 358 500 Work equipment......................................................................................... 361 Blade.................................................................................................. 362 Cutting edge and end bit............................................................................... 370 Ripper (Multi shank)................................................................................... 372 Ripper (Single shank).................................................................................. 373 Hydraulic cylinder..................................................................................... 374 Piston valve........................................................................................... 378 600 Cab and its attachme................................................................................... 381 Cab mount.............................................................................................. 382 Cab.................................................................................................... 383 Subextremely cold spec. cab (subextremely cold weather spec.).......................................... 384 FRP canopy mount....................................................................................... 385 FRP canopy............................................................................................. 386 700 Electrical system...................................................................................... 389 Monitor system......................................................................................... 390 Engine control system.................................................................................. 406 Cooling system control system.......................................................................... 409 Electronic steering control system..................................................................... 411 KOMTRAX system......................................................................................... 414 KOMTRAX terminal (for GPRS)............................................................................ 416 System components...................................................................................... 417 Sensor................................................................................................. 425 20 Standard value table........................................................................................ 433 100 Standard service value table........................................................................... 433 Standard service value table for engine................................................................ 434 Standard service value table for chassis............................................................... 436 30 Testing and adjusting....................................................................................... 451 101 Testing and adjusting, Part 1.......................................................................... 451 Precautions before work................................................................................ 452 Tools for testing, adjusting, and troubleshooting...................................................... 453 Testing engine speed................................................................................... 456 Testing intake air pressure (boost pressure)........................................................... 458 Testing exhaust temperature............................................................................ 460 Testing exhaust gas color.............................................................................. 462 Adjusting valve clearance.............................................................................. 463 Testing compression pressure........................................................................... 465 Testing blow-by pressure............................................................................... 469 Testing engine oil pressure............................................................................ 470 Handling of fuel system devices........................................................................ 471 Releasing residual pressure from fuel system........................................................... 471 Testing fuel pressure.................................................................................. 472 Testing fuel return and leak amount.................................................................... 477 Bleeding air from fuel circuit......................................................................... 479 Testing fuel circuit for leakage....................................................................... 480 Handling of reduced cylinder mode operation............................................................ 481 Handling of no injection cranking operation............................................................ 481 Testing and adjusting air conditioner compressor belt tension.......................................... 482 Replacing alternator belt.............................................................................. 483 Adjusting fuel control dial and decelerator pedal...................................................... 484 Handling controller high-voltage circuit............................................................... 485 102 Testing and adjusting, Part 2.......................................................................... 487 Testing power train oil pressure....................................................................... 489 Adjusting transmission output shaft speed sensor (replacement procedure)............................... 494 Simple test procedure for brake performance............................................................ 495 Adjusting brake pedal.................................................................................. 496 Adjusting parking brake lever.......................................................................... 498 Emergency escape method when power train has trouble................................................... 500 Adjusting clearance of idler........................................................................... 503 Adjusting clearance of idler (without idler support automatic thrust adjustment)...................... 504 Inspecting wear of sprocket............................................................................ 505 Testing and adjusting track shoe tension............................................................... 506 Testing and adjusting work equipment and HSS oil pressure.............................................. 507 Testing control circuit basic pressure................................................................. 510 Testing PPC valve output pressure...................................................................... 511 Adjusting work equipment PPC valve play................................................................ 513 Testing internal leakage of work equipment cylinder.................................................... 517 Bleeding air from work equipment cylinder.............................................................. 518 Releasing residual pressure from work equipment cylinder............................................... 518 Checking parts which caused hydraulic drift of blade or ripper......................................... 519 Adjusting work equipment lock lever.................................................................... 520 Adjusting work equipment lock lever (FRP canopy specification)......................................... 521 Testing fan speed...................................................................................... 523 Testing fan circuit oil pressure....................................................................... 524 Bleeding air from fan pump............................................................................. 525 Bleeding air from HSS pump............................................................................. 526 Adjusting straight tiltdozer........................................................................... 527 Adjusting play of blade center ball1................................................................... 529 Adjusting operator’s cab............................................................................... 530 103 Testing and adjusting, Part 3.......................................................................... 535 Special functions of machine monitor (EMMS)............................................................ 536 104 Testing and adjusting, Part 4.......................................................................... 593 Handling of voltage circuit of engine controller....................................................... 594 Adjustment method when controller has been replaced.................................................... 595 Preparation work for troubleshooting of electrical system.............................................. 597 Inspection procedure of diode.......................................................................... 601 Pm-Clinic service...................................................................................... 602 40 Troubleshooting............................................................................................. 617 100 Failure code table and fuse locations.................................................................. 617 Precautions before work................................................................................ 618 Failure codes table.................................................................................... 619 Fuse locations......................................................................................... 624 200 General information on troubleshooting................................................................. 627 Points to remember when troubleshooting................................................................ 628 How to proceed troubleshooting......................................................................... 629 Checks before troubleshooting.......................................................................... 630 Classification and procedures for troubleshooting...................................................... 632 Symptom supposed to be failure and troubleshooting No.................................................. 636 Information contained in troubleshooting table......................................................... 638 Troubleshooting method for disconnecting wiring harness of pressure sensor system...................... 640 Connector list and stereogram.......................................................................... 642 Connection table for connector pin numbers............................................................. 656 T- branch box and T- branch adapter table.............................................................. 692 301 Troubleshooting by failure code (Display of code), Part 1.............................................. 697 Failure code [1500L0] Transmission clutch: Abnormal.................................................... 699 Failure code [15SAL1] Forward clutch: Fill high........................................................ 700 Failure code [15SALH] Forward clutch: Fill low......................................................... 702 Failure code [15SBL1] Reverse clutch: Fill high........................................................ 704 Failure code [15SBLH] Reverse clutch: Fill low......................................................... 706 Failure code [15SEL1] Speed 1st clutch: Fill high...................................................... 708 Failure code [15SELH] Speed 1st clutch: Fill low....................................................... 710 Failure code [15SFL1] Speed 2nd clutch: Fill high...................................................... 712 Failure code [15SFLH] Speed 2nd clutch: Fill low....................................................... 714 Failure code [15SGL1] Speed 3rd clutch: Fill high...................................................... 716 Failure code [15SGLH] Speed 3rd clutch: Fill low....................................................... 718 Failure code [15SJL1] L/U: Fill high................................................................... 720 Failure code [15SJLH] L/U: Fill low.................................................................... 722 Failure code [AB00MA] Battery Charge Abnormal.......................................................... 724 Failure code [B@BAZG] Eng Oil Press Low................................................................ 726 Failure code [B@BCNS] Eng Water Overheat............................................................... 726 Failure code [B@CENS] T/C Oil Overheat................................................................. 727 Failure code [B@HANS] Hyd Oil Overheat................................................................. 727 302 Troubleshooting by failure code (Display of code), Part 2.............................................. 729 Failure code [CA111] ECM Critical Internal Failure..................................................... 731 Failure code [CA115] Eng Ne and Bkup Speed Sens Error.................................................. 731 Failure code [CA122] Chg Air Press Sensor High Error................................................... 732 Failure code [CA123] Chg Air Press Sensor Low Error.................................................... 734 Failure code [CA131] Throttle Sensor High Error........................................................ 736 Failure code [CA132] Throttle Sensor Low Error......................................................... 738 Failure code [CA144] Coolant Temp Sens High Error...................................................... 740 Failure code [CA145] Coolant Temp Sens Low Error....................................................... 742 Failure code [CA153] Chg Air Temp Sensor High Error.................................................... 744 Failure code [CA154] Chg Air Temp Sensor Low Error..................................................... 746 Failure code [CA155] Chg Air Temp High Speed Derate.................................................... 748 Failure code [CA187] Sens Supply 2 Volt Low Error...................................................... 750 Failure code [CA221] Ambient Press Sens High Error..................................................... 752 Failure code [CA222] Ambient Press Sens Low Error...................................................... 754 Failure code [CA227] Sens Supply 2 Volt High Error..................................................... 756 Failure code [CA234] Eng Overspeed..................................................................... 756 Failure code [CA238] Ne Speed Sens Supply Volt Error................................................... 757 Failure code [CA271] IMV/PCV1 Short Error.............................................................. 758 Failure code [CA272] IMV/PCV1 Open Error............................................................... 760 Failure code [CA281] Abnormal supply pump pressure balance............................................. 762 Failure code [CA322] Inj #1(L#1) Open/Short Error...................................................... 764 Failure code [CA323] Inj #5(L#5) Open/Short Error...................................................... 766 Failure code [CA324] Inj #3(L#3) Open/Short Error...................................................... 768 Failure code [CA325] Inj #6(L#6) Open/Short Error...................................................... 770 Failure code [CA331] Inj #2(L#2) Open/Short Error...................................................... 772 Failure code [CA332] Inj #4(L#4) Open/Short Error...................................................... 774 303 Troubleshooting by failure code (Display of code), Part 3.............................................. 777 Failure code [CA342] Calibration Code Incompatibility.................................................. 779 Failure code [CA351] Injectors Drive Circuit Error..................................................... 779 Failure code [CA352] Sens Supply 1 Volt Low Error...................................................... 780 Failure code [CA386] Sens Supply 1 Volt High Error..................................................... 782 Failure code [CA428] Water in Fuel Sensor High Error................................................... 784 Failure code [CA429] Water in Fuel Sensor Low Error.................................................... 786 Failure code [CA435] Eng Oil Press Sw Error............................................................ 788 Failure code [CA441] Battery Voltage Low Error......................................................... 790 Failure code [CA442] Battery Voltage High Error........................................................ 792 Failure code [CA449] Rail Press Very High Error........................................................ 794 Failure code [CA451] Rail Press Sensor High Error...................................................... 796 Failure code [CA452] Rail Press Sensor Low Error....................................................... 798 Failure code [CA488] Chg Air Temp High Torque Derate................................................... 800 Failure code [CA553] Rail Press High Error............................................................. 801 Failure code [CA559] Rail Press Low Error.............................................................. 802 Failure code [CA689] Eng Ne Speed Sensor Error......................................................... 804 Failure code [CA731] Eng Bkup Speed Sens Phase Error................................................... 808 Failure code [CA757] All Continuous Data Lost Error.................................................... 809 Failure code [CA778] Eng Bkup Speed Sensor Error....................................................... 810 Failure code [CA1633] KOMNET Datalink Timeout Error.................................................... 813 Failure code [CA2185] Throt Sens Sup Volt High Error................................................... 814 Failure code [CA2186] Throt Sens Sup Volt Low Error.................................................... 816 Failure code [CA2249] Rail Press Very Low Error........................................................ 818 Failure code [CA2265] Fuel Feed Pump Open Error........................................................ 820 Failure code [CA2266] Fuel Feed Pump Short Error....................................................... 822 Failure code [CA2311] IMV Solenoid Error............................................................... 823 Failure code [CA2555] Grid Htr Relay Volt High Error................................................... 824 Failure code [CA2556] Grid Htr Relay Volt Low Error.................................................... 826 304 Troubleshooting by failure code (Display of code), Part 4.............................................. 829 Failure code [D110KB] Battery relay drive: Short circuit............................................... 832 Failure code [D130KA] Neutral relay: Disconnection..................................................... 834 Failure code [D130KB] Neutral relay: Short circuit..................................................... 836 Failure code [D161KA] Back-up alarm relay: Disconnection............................................... 838 Failure code [D161KB] Back-up alarm relay: Short circuit............................................... 840 Failure code [D862KA] GPS Antenna Open Circuit......................................................... 842 Failure code [DAFRKR] CAN Disconnection................................................................ 843 Failure code [DAFRMC] CAN Discon (Monitor Detected).................................................... 844 Failure code [DB2RKR] CAN Disconnection................................................................ 847 Failure code [DBE0KT] PT controller: Abnormality in controller......................................... 852 Failure code [DBE1KK] Battery direct Source voltage reduction.......................................... 854 Failure code [DBE2KK] Solenoid Source voltage reduction................................................ 856 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction........................................ 858 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction........................................... 860 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction........................................ 862 Failure code [DBE9KQ] PT controller: Type select signal................................................ 864 Failure code [DD12KA] Shift up Sw: Disconnection....................................................... 866 Failure code [DD12KB] Shift up Sw: Short circuit....................................................... 868 Failure code [DD13KA] Shift down Sw: Disconnection..................................................... 870 Failure code [DD13KB] Shift down Sw: Short circuit..................................................... 872 Failure code [DD14KA] Parking lever Sw: Disconnection.................................................. 874 Failure code [DD14KB] Parking lever Sw: Short circuit.................................................. 876 305 Troubleshooting by failure code (Display of code), Part 5.............................................. 879 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection................................................ 882 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit................................................ 884 Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection.................................................. 886 Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit.................................................. 888 Failure code [DDNLKA] Weq lock Sw: Disconnection....................................................... 890 Failure code [DDNLKB] Weq lock Sw: Short circuit....................................................... 892 Failure code [DGS1KX] Hyd oil temp sensor: Abnormal.................................................... 894 Failure code [DGT1KA] T/C oil temp sensor: Disconnection............................................... 896 Failure code [DGT1KX] T/C oil temp sensor: Short circuit............................................... 898 Failure code [DH21KA] Weq pressure sensor: Disconnection............................................... 900 Failure code [DH21KB] Weq pressure sensor: Short circuit............................................... 902 Failure code [DHT5KA] T/C pressure sensor: Disconnection............................................... 904 Failure code [DHT5KB] T/C pressure sensor: Short circuit............................................... 906 Failure code [DK10KA] Fuel control Dial: Disconnection................................................. 908 Failure code [DK10KB] Fuel control Dial: Short circuit................................................. 910 Failure code [DK30KA] ST lever 1: Disconnection........................................................ 912 Failure code [DK30KB] ST lever 1: Short circuit........................................................ 914 Failure code [DK30KX] ST lever: Out of normal range.................................................... 916 Failure code [DK30KZ] ST lever: Disconnection or short circuit......................................... 916 Failure code [DK30L8] ST lever: Signal mismatch........................................................ 917 Failure code [DK31KA] ST lever 2: Disconnection........................................................ 918 Failure code [DK31KB] ST lever 2: Short circuit........................................................ 920 Failure code [DK40KA] Brake potentiometer: Disconnection............................................... 922 Failure code [DK40KB] Brake potentiometer: Short circuit............................................... 924 Failure code [DK55KX] FR lever: Out of normal range.................................................... 926 Failure code [DK55KZ] FR lever: Disconnection or short circuit......................................... 926 Failure code [DK55L8] FR lever: Signal mismatch........................................................ 927 Failure code [DK56KA] FR lever 1: Disconnection........................................................ 928 Failure code [DK56KB] FR lever 1: Short circuit........................................................ 930 Failure code [DK57KA] FR lever 2: Disconnection........................................................ 932 Failure code [DK57KB] FR lever 2: Short circuit........................................................ 934 306 Troubleshooting by failure code (Display of code), Part 6.............................................. 937 Failure code [DKH1KA] Pitch angle sensor: Disconnection................................................ 940 Failure code [DKH1KB] Pitch angle sensor: Short circuit................................................ 942 Failure code [DLT3KA] T/M out-speed sensor: Disconnection.............................................. 944 Failure code [DLT3KB] T/M out-speed sensor: Abnormal................................................... 945 Failure code [DW5AKA] Pitch selector Sol.: Disconnection............................................... 946 Failure code [DW5AKB] Pitch selector Sol.: Short circuit............................................... 947 Failure code [DW5AKY] Pitch selector Sol.: Short circuit............................................... 948 Failure code [DW7BKA] Fan rev EPC: Disconnection....................................................... 950 Failure code [DW7BKB] Fan rev EPC: Short circuit....................................................... 951 Failure code [DWN1KA] Hss EPC1: Disconnection.......................................................... 952 Failure code [DWN1KB] Hss EPC1: Short circuit.......................................................... 953 Failure code [DWN1KY] Hss EPC1: Short circuit.......................................................... 954 Failure code [DWN2KA] Hss EPC2: Disconnection.......................................................... 955 Failure code [DWN2KB] Hss EPC2: Short circuit.......................................................... 956 Failure code [DWN2KY] Hss EPC2: Short circuit.......................................................... 957 Failure code [DWN5KA] Fan pump solenoid: Disconnection................................................. 958 Failure code [DWN5KB] Fan pump solenoid: Short circuit................................................. 959 Failure code [DWN5KY] Fan control solenoid: Short circuit.............................................. 960 Failure code [DXA0KA] TVC Sol.: Disconnection.......................................................... 962 Failure code [DXA0KB] TVC Sol.: Short circuit.......................................................... 963 Failure code [DXA0KY] TVC Sol.: Short circuit.......................................................... 964 Failure code [DXH1KA] Lock-up ECMV: Disconnection...................................................... 965 Failure code [DXH1KB] Lock-up ECMV: Short circuit...................................................... 966 Failure code [DXH1KY] Lock-up ECMV: Short circuit...................................................... 968 Failure code [DXH4KA] 1st clutch ECMV: Disconnection................................................... 970 Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................... 971 Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................... 972 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection................................................... 973 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit................................................... 974 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit................................................... 975 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection................................................... 976 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................... 977 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit................................................... 978 Failure code [DXH7KA] R clutch ECMV: Disconnection..................................................... 979 Failure code [DXH7KB] R clutch ECMV: Short circuit..................................................... 980 Failure code [DXH7KY] R clutch ECMV: Short circuit..................................................... 982 Failure code [DXH8KA] F clutch ECMV: Disconnection..................................................... 984 Failure code [DXH8KB] F clutch ECMV: Short circuit..................................................... 985 Failure code [DXH8KY] F clutch ECMV: Short circuit..................................................... 986 Failure code [DXJ4KA] Weq lock Sol.: Disconnection..................................................... 988 Failure code [DXJ4KB] Weq lock Sol.: Short circuit..................................................... 989 400 Troubleshooting of electrical system (E-mode).......................................................... 991 Before troubleshooting of electrical system............................................................ 993 Information in troubleshooting table................................................................... 995 E-1 Engine does not start (starting motor does not turn)............................................... 997 E-2 Preheater does not operate.........................................................................1000 E-3 When starting switch is turned ON, machine monitor displays nothing................................1006 E-4 When starting switch is turned ON (before starting engine), basic check item lights up.............1008 E-5 Precaution item lights up while engine is running..................................................1010 E-6 Emergency stop item lights up while engine is running..............................................1012 E-7 Engine coolant temperature gauge does not indicate normally........................................1014 E-8 Fuel gauge does not indicate properly..............................................................1016 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally.........................1019 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally..............................1020 E-11 Contents of display by machine monitor are different from applicable machine......................1021 E-12 Machine monitor does not display some items.......................................................1021 E-13 Function switch does not work.....................................................................1021 E-14 Operation mode does not change....................................................................1022 E-15 Gearshift mode does not change....................................................................1022 E-16 Customize function does not operate normally......................................................1023 E-17 Customize memory function does not operate normally...............................................1023 E-18 Alarm buzzer does not sound or does not stop......................................................1024 E-19 When starting switch is turned OFF, service meter is not displayed................................1024 E-20 Machine monitor cannot be set in service mode.....................................................1024 E-21 Horn does not sound or does not stop..............................................................1025 E-22 Back-up alarm does not sound or does not stop.....................................................1026 E-23 Head lamp or rear lamp does not light up..........................................................1028 E-24 Windshield wiper does not operate.................................................................1032 E-25 Window washer does not operate....................................................................1046 E-26 KOMTRAX system does not operate correctly.........................................................1051 500 Troubleshooting of hydraulic and mechanical system (H-mode)............................................1053 Failure mode and cause table...........................................................................1054 Contents of troubleshooting table......................................................................1056 H-1 There is no travel power (no drawbar pull).........................................................1057 H-2 Machine does not move (at 2nd or 3rd speed)........................................................1058 H-3 Machine does not move at any gear speed............................................................1059 H-4 Machine travels only in one direction, forward or in reverse.......................................1060 H-5 When gear is shifted or travel direction is changed, large time lag is made........................1061 H-6 Machine cannot be steered (Machine does not turn leftward or rightward)............................1062 H-7 Steering speed or power is low.....................................................................1062 H- 8 Brake does not work...............................................................................1063 H-9 Overheat of power train oil........................................................................1064 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor.....................1065 H-11 All work equipment speeds are slow................................................................1065 H-12 Work equipment does not move......................................................................1066 H-13 Blade lift speed is slow or lacks power...........................................................1066 H-14 Blade tilt speed is slow or lacks power...........................................................1067 H-15 Ripper lift speed is slow or lacks power..........................................................1067 H-16 Excessive hydraulic drift of blade lift...........................................................1068 H-17 Excessive hydraulic drift of blade tilt...........................................................1068 H-18 Excessive hydraulic drift of ripper lift..........................................................1069 600 Troubleshooting of engine (S-mode).....................................................................1071 Method of using troubleshooting charts.................................................................1073 S-1 Starting performance is poor.......................................................................1076 S-2 Engine does not start..............................................................................1077 S-3 Engine does not pick up smoothly...................................................................1080 S-4 Engine stops during operations.....................................................................1081 S-5 Engine does not rotate smoothly....................................................................1082 S-6 Engine lacks output (or lacks power)...............................................................1083 S-7 Exhaust smoke is black (incomplete combustion).....................................................1084 S-8 Oil consumption is excessive (or exhaust smoke is blue)............................................1085 S-9 Oil becomes contaminated quickly...................................................................1086 S-10 Fuel consumption is excessive.....................................................................1087 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)............................1088 S-12 Oil pressure drops................................................................................1089 S-13 Oil level rises (water, fuel in oil)..............................................................1090 S-14 Coolant temperature becomes too high (overheating)................................................1091 S-15 Abnormal noise is made............................................................................1092 S-16 Vibration is excessive............................................................................1093 50 Disassembly and assembly....................................................................................1095 100 General information on disassembly and assembly........................................................1095 Precautions before work................................................................................1096 How to read this manual................................................................................1097 Coating materials list.................................................................................1099 Special tool list......................................................................................1102 Sketches of special tools..............................................................................1112 200 Engine and cooling system..............................................................................1129 Removal and installation of fuel supply pump assembly..................................................1130 Removal and installation of fuel injector assembly.....................................................1135 Removal and installation of cylinder head assembly.....................................................1145 Removal and installation of radiator assembly..........................................................1160 Removal and installation of aftercooler assembly.......................................................1163 Removal and installation of hydraulic oil cooler assembly..............................................1165 Removal and installation of power train oil cooler assembly............................................1167 Removal and installation of cooling fan drive assembly.................................................1170 Removal and installation of cooling fan motor assembly.................................................1172 Removal and installation of main body of coolant preheater (subextremely cold weather spec)............1174 Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.)..............1178 Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)..........1180 Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.).......1184 Removal and installation of damper assembly............................................................1193 Removal and installation of engine front oil seal......................................................1196 Removal and installation of engine rear oil seal.......................................................1200 Removal and installation of engine hood assembly.......................................................1208 Removal and installation of fuel tank assembly.........................................................1210 300 Power train............................................................................................1213 Removal and installation of power train unit assembly..................................................1214 Separation and connection of power train unit assembly.................................................1218 Disassembly and assembly of PTO assembly...............................................................1223 Disassembly and assembly of torque converter assembly..................................................1228 Disassembly and assembly of transmission assembly......................................................1239 Disassembly and assembly of HSS assembly...............................................................1266 Removal and installation of final drive assembly.......................................................1286 Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)....1288 Disassembly and assembly of final drive assembly.......................................................1290 Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type)....1298 400 Undercarriage and frame................................................................................1313 Removal and installation of track frame assembly.......................................................1314 Removal and installation of idler assembly.............................................................1316 Removal and installation of idler assembly (Without idler support automatic thrust adjustment).........1318 Disassembly and assembly of idler assembly.............................................................1320 Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment).........1324 Removal and installation of recoil spring assembly.....................................................1329 Disassembly and assembly of recoil spring assembly.....................................................1330 Removal and installation of track roller assembly......................................................1334 Disassembly and assembly of track roller assembly......................................................1335 Removal and installation of carrier roller assembly....................................................1339 Disassembly and assembly of carrier roller assembly....................................................1340 Expansion and installation of track shoe assembly (Conventional type track shoe).......................1343 Expansion and installation of track shoe assembly (PLUS type track shoe)...............................1346 Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe).............1347 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe).....................1361 Field disassembly and assembly of one link (Conventional type track shoe)..............................1373 Field disassembly and assembly of one link (PLUS type track shoe)......................................1380 Removal and installation of pivot shaft assembly.......................................................1385 Removal and installation of equalizer bar assembly.....................................................1386 Disassembly and assembly of equalizer bar side bushing.................................................1388 500 Hydraulic system.......................................................................................1391 Removal and installation of hydraulic tank assembly....................................................1392 Removal and installation of control valve assembly.....................................................1395 Disassembly and assembly of control valve assembly.....................................................1398 Disassembly and assembly of blade lift and tilt PPC valve assembly.....................................1400 Disassembly and assembly of ripper PPC valve assembly..................................................1401 Removal and installation of HSS and cooling fan pump assembly..........................................1402 Removal and installation of power train and lubrication pump assembly..................................1404 Removal and installation of scavenging pump assembly...................................................1406 Removal and installation of HSS motor assembly.........................................................1407 Disassembly and assembly of hydraulic cylinder assembly................................................1410 600 Work equipment.........................................................................................1417 Removal and installation of blade assembly (ST-TPP dozer)..............................................1418 Removal and installation of blade assembly (PAT dozer).................................................1421 Removal and installation of ripper assembly............................................................1424 700 Cab and its attachments................................................................................1429 Removal and installation of ROPS cab assembly..........................................................1430 Removal and installation of operator’s cab glass (Stuck glass).........................................1437 Removal and installation of floor frame assembly (FRP canopy specification)............................1438 Removal and installation of operator’s cab glass (Stuck glass).........................................1442 Removal and installation of air conditioner unit assembly..............................................1448 Removal and installation of air conditioner compressor assembly........................................1452 800 Electrical system......................................................................................1455 Removal and installation of monitor panel assembly.....................................................1456 Removal and installation of engine controller assembly.................................................1458 Removal and installation of power train controller assembly............................................1460 Removal and installation of KOMTRAX terminal assembly..................................................1462 80 Appendix....................................................................................................1465 100 Air conditioner........................................................................................1465 Precautions before work................................................................................1467 Air conditioner component..............................................................................1468 Configuration and function of refrigerating cycle......................................................1470 Outline of refrigerating cycle.........................................................................1471 Air conditioner unit...................................................................................1474 Control plate..........................................................................................1478 Compressor.............................................................................................1479 Condenser..............................................................................................1480 Receiver drier.........................................................................................1481 Caution about refrigerant..............................................................................1482 Troubleshooting procedure..............................................................................1483 Block diagram..........................................................................................1484 Circuit diagram and arrangement of connector pins......................................................1486 Detail of air conditioner unit.........................................................................1488 Parts and connectors arrangement.......................................................................1490 Testing air leakage (duct).............................................................................1496 Testing with self-diagnosis function...................................................................1498 Testing temperature control............................................................................1501 Testing vent (mode) changeover.........................................................................1503 Testing Recirc/Fresh changeover........................................................................1506 Testing inner sensor...................................................................................1507 Testing evaporator temperature sensor..................................................................1508 Testing sunlight sensor................................................................................1511 Testing (dual) pressure switch for refrigerant.........................................................1512 Testing relays and diodes..............................................................................1514 Troubleshooting chart 1................................................................................1516 Troubleshooting chart 2................................................................................1517 Troubleshooting for electrical system (E mode).........................................................1520 Troubleshooting with gauge pressure....................................................................1536 Connection of service tool.............................................................................1539 Precautions for connecting air conditioner piping......................................................1540 Handling of compressor oil.............................................................................1541 90 Diagrams and drawings.......................................................................................1545 100 Hydraulic diagrams and drawings........................................................................1545 Power train hydraulic circuit diagram..................................................................1547 Work equipment hydraulic circuit diagram...............................................................1551 200 Electrical diagrams and drawings.......................................................................1561 Electrical circuit diagram.............................................................................1563 Electrical circuit diagram (Sand terrain specification)................................................1601 Electrical circuit diagram (FRP canopy specification)..................................................1607
DESCRIPTION:
KOMATSU D65EX-16 D65PX-16 D65WX-16 BULLDOZER SHOP MANUAL SEN04887-18 – PDF DOWNLOAD
General precautions
1) Before carrying out any greasing or repairs, read all the safety labels stuck to the machine. For the locations of the safety labels and detailed explanation of precautions, see the Operation and Maintenance Manual.
2) Decide a place in the repair workshop to keep tools and removed parts. Always keep the tools and parts in their correct places. Always keep the work area clean and make sure that there is no dirt, water, or oil on the floor. Smoke only in the areas provided for smoking. Never smoke while working.
3) When carrying out any operation, always wear safety shoes and helmet. Do not wear loose work clothes, or clothes with buttons missing.
A. Always wear safety glasses when hitting parts with a hammer.
B. Always wear safety glasses when grinding parts with a grinder, etc.
4) When carrying out any operation with 2 or more workers, always agree on the operating procedure before starting. Always inform your fellow workers before starting any step of the operation. Before starting work, hang UNDER REPAIR warning signs in the operator’s compartment.
5) Only the approved personnel can do the work in a closed environment or in a prohibited area.
6) Only qualified workers must carry out work and operation which require license or qualification.
7) Keep all tools in good condition, learn the correct way to use them, and use the proper ones of them. Before starting work, thoroughly check the tools, machine, forklift, service car, etc.
8) If welding repairs are needed, always have a trained and experienced welder carry out the work. When carrying out welding work, always wear welding gloves, apron, shielding goggles, cap and other clothes suited for welding work.
9) Before starting work, warm up your body thoroughly to start work under good condition.
10) Avoid continuing work for long hours and take rests at proper intervals to keep your body in good condition. Take rests in specified safe places.
11) When you work in high places, use a platform.
12) Before you start the work, use the personal fall-arrest equipment to prevent falling. There is a danger of personal accident that you fall by slipping.
13) Always do the work correctly. If you find the unsafe behavior of co-worker, give him/her a notice and stop it.
14) Because there is a danger that you are caught, be very careful when the work is done in dangerous areas such as: when you go in the range where the lifted load possibly falls, or when you stand directly in front of tire, or when you are near the sliding parts.
15) When you handle chemical materials (such as nitrogen gas), see the MSDS (safety data sheet) and local guidelines, and get the important information (such as a safe handling method). Also, put on applicable protective equipment (such as protective goggles, gloves, and masks).
S.S 30/12/24
