Komatsu D65EX-16, D65PX-16, D65WX-16 80001 & Up SEN04887-09 (Preview)
COVER
00 Index and foreword
100 Index
Composition of shop manual
Table of contents
200 Foreword and general information
Safety notice
How to read the shop manual
Explanation of terms for maintenance standard
Handling of electric equipment and hydraulic component
Handling of connectors newly used for engines
How to read electric wire code
Precautions when carrying out operation
Method of disassembling and connecting push-pull type coupler
Standard tightening torque table
Conversion table
01 General
100 Specification and technical data
Specification dimension drawing
Specifications
Weight table
Table of fuel, coolant and lubricants
10 Structure, function and maintenance standard
100 Engine and cooling system
Engine mount
Cooling system
Cooling fan pump
Cooling fan motor
Coolant preheater (subextremely cold weather spec.)
201 Power train, Part 1
Power train
HSS system
Overall view of power train unit
Power train hydraulic piping diagram
Transmission, steering and brake control
Damper
Universal joint
Torque converter and PTO
Transmission
Transmission control valve
ECMV
Main relief and torque converter relief valve
Main relief and torque converter relief valve (subextremely cold weather spec.)
Transmission lubrication relief valve
202 Power train, Part 2
Bevel gear shaft, HSS and brake
Brake valve
Final drive
Final drive (Planetary gear installed inside of sprocket type)
300 Undercarriage and frame
Main frame
Suspension
Track frame and idler cushion
Idler
Track roller
Carrier roller
Sprocket
Track shoe
401 Hydraulic system, Part 1
Work equipment hydraulic system layout drawing
Work equipment control
Hydraulic tank and filter
Scavenging pump
Power train and steering lubrication pump
HSS pump
HSS motor
402 Hydraulic system, Part 2
Control valve
CLSS
Function and operation of each valve
403 Hydraulic system, Part 3
PPC valve (blade lift, blade tilt)
PPC valve (ripper)
Electric lever (steering)
Quick drop valve
Work equipment lock solenoid valve
Pitch selector solenoid valve
Hydraulic oil cooler bypass valve
Accumulator
500 Work equipment
Blade
Cutting edge and end bit
Ripper (Multi shank)
Ripper (Single shank)
Hydraulic cylinder
Piston valve
600 Cab and its attachme
Cab mount
Cab
Subextremely cold spec. cab (subextremely cold weather spec.)
600 Cab and its attachmentsFRP canopy mountFRP canopy mount
FRP canopy
700 Electrical system
Monitor system
Engine control system
Cooling system control system
Electronic steering control system
KOMTRAX system
KOMTRAX terminal (for GPRS)
System components
Sensor
20 Standard value table
100 Standard service value table
Standard service value table for engine
Standard service value table for chassis
30 Testing and adjusting
101 Testing and adjusting, Part 1
Tools for testing, adjusting, and troubleshooting
Testing engine speed
Testing intake air pressure (boost pressure)
Testing exhaust temperature
Testing exhaust gas color
Adjusting valve clearance
Testing compression pressure
Testing blow-by pressure
Testing engine oil pressure
Handling of fuel system devices
Releasing residual pressure from fuel system
Testing fuel pressure
Testing fuel return and leak amount
Bleeding air from fuel circuit
Testing fuel circuit for leakage
Handling of reduced cylinder mode operation
Handling of no injection cranking operation
Testing and adjusting air conditioner compressor belt tension
Replacing alternator belt
Adjusting fuel control dial and decelerator pedal
Handling controller high-voltage circuit
102 Testing and adjusting, Part 2
Testing power train oil pressure
Adjusting transmission output shaft speed sensor (replacement procedure)
Simple test procedure for brake performance
Adjusting brake pedal
Adjusting parking brake lever
Emergency escape method when power train has trouble
Adjusting clearance of idler
Inspecting wear of sprocket
Inspecting wear of sprocket
Testing and adjusting track shoe tension
Testing and adjusting work equipment and HSS oil pressure
Testing control circuit basic pressure
Testing PPC valve output pressure
Adjusting work equipment PPC valve play
Testing internal leakage of work equipment cylinder
Bleeding air from work equipment cylinder
Releasing residual pressure from work equipment cylinder
Checking parts which caused hydraulic drift of blade or ripper
Adjusting work equipment lock lever
Adjusting work equipment lock lever (FRP canopy specification)
Testing fan speed
Testing fan circuit oil pressure
Bleeding air from fan pump
Bleeding air from HSS pump
Adjusting straight tiltdozer
Adjusting play of blade center ball1
Adjusting operator’s cab
103 Testing and adjusting, Part 3
Special functions of machine monitor (EMMS)
104 Testing and adjusting, Part 4
Handling of voltage circuit of engine controller
Adjustment method when controller has been replaced
Preparation work for troubleshooting of electrical
Inspection procedure of diode
Pm-Clinic service
40 Troubleshooting
100 Failure code table and fuse locations
Failure codes table
Fuse locations
200 General information on troubleshooting
Points to remember when troubleshooting
How to proceed troubleshooting
Checks before troubleshooting
Classification and procedures for troubleshooting
Symptom supposed to be failure and troubleshooting No.
Information contained in troubleshooting table
Troubleshooting method for disconnecting wiring harness of pressure sensor system
Connector list and stereogram
Connection table for connector pin numbers
T- branch box and T- branch adapter table
301 Troubleshooting by failure code (Display of code), Part 1
Failure code [1500L0] Transmission clutch: Abnormal
Failure code [15SAL1] Forward clutch: Fill high
Failure code [15SALH] Forward clutch: Fill low
Failure code [15SBL1] Reverse clutch: Fill high
Failure code [15SBLH] Reverse clutch: Fill low
Failure code [15SEL1] Speed 1st clutch: Fill high
Failure code [15SELH] Speed 1st clutch: Fill low
Failure code [15SFL1] Speed 2nd clutch: Fill high
Failure code [15SFLH] Speed 2nd clutch: Fill low
Failure code [15SGL1] Speed 3rd clutch: Fill high
Failure code [15SGLH] Speed 3rd clutch: Fill low
Failure code [15SJL1] L/U: Fill high
Failure code [15SJLH] L/U: Fill low
Failure code [AB00MA] Battery Charge Abnormal
Failure code [B@BAZG] Eng Oil Press Low
Failure code [B@BCNS] Eng Water Overheat
Failure code [B@CENS] T/C Oil Overheat
Failure code [B@HANS] Hyd Oil Overheat
302 Troubleshooting by failure code (Display of code), Part 2
Failure code [CA111] ECM Critical Internal Failure
Failure code [CA115] Eng Ne and Bkup Speed Sens Error
Failure code [CA122] Chg Air Press Sensor High Error
Failure code [CA123] Chg Air Press Sensor Low Error
Failure code [CA131] Throttle Sensor High Error
Failure code [CA132] Throttle Sensor Low Error
Failure code [CA144] Coolant Temp Sens High Error
Failure code [CA145] Coolant Temp Sens Low Error
Failure code [CA153] Chg Air Temp Sensor High Error
Failure code [CA154] Chg Air Temp Sensor Low Error
Failure code [CA155] Chg Air Temp High Speed Derate
Failure code [CA187] Sens Supply 2 Volt Low Error
Failure code [CA221] Ambient Press Sens High Error
Failure code [CA222] Ambient Press Sens Low Error
Failure code [CA227] Sens Supply 2 Volt High Error
Failure code [CA234] Eng Overspeed
Failure code [CA238] Ne Speed Sens Supply Volt Error
Failure code [CA271] IMV/PCV1 Short Error
Failure code [CA272] IMV/PCV1 Open Error
Failure code [CA281] Abnormal supply pump pressure balance
Failure code [CA322] Inj #1(L#1) Open/Short Error
Failure code [CA323] Inj #5(L#5) Open/Short Error
Failure code [CA324] Inj #3(L#3) Open/Short Error
Failure code [CA325] Inj #6(L#6) Open/Short Error
Failure code [CA331] Inj #2(L#2) Open/Short Error
Failure code [CA332] Inj #4(L#4) Open/Short Error
303 Troubleshooting by failure code (Display of code), Part 3
Failure code [CA342] Calibration Code Incompatibility
Failure code [CA351] Injectors Drive Circuit Error
Failure code [CA352] Sens Supply 1 Volt Low Error
Failure code [CA386] Sens Supply 1 Volt High Error
Failure code [CA428] Water in Fuel Sensor High Error
Failure code [CA429] Water in Fuel Sensor Low Error
Failure code [CA435] Eng Oil Press Sw Error
Failure code [CA441] Battery Voltage Low Error
Failure code [CA442] Battery Voltage High Error
Failure code [CA449] Rail Press Very High Error
Failure code [CA451] Rail Press Sensor High Error
Failure code [CA452] Rail Press Sensor Low Error
Failure code [CA488] Chg Air Temp High Torque Derate
Failure code [CA553] Rail Press High Error
Failure code [CA559] Rail Press Low Error
Failure code [CA689] Eng Ne Speed Sensor Error
Failure code [CA731] Eng Bkup Speed Sens Phase Error
Failure code [CA757] All Continuous Data Lost Error
Failure code [CA778] Eng Bkup Speed Sensor Error
Failure code [CA1633] KOMNET Datalink Timeout Error
Failure code [CA2185] Throt Sens Sup Volt High Error
Failure code [CA2186] Throt Sens Sup Volt Low Error
Failure code [CA2249] Rail Press Very Low Error
Failure code [CA2265] Fuel Feed Pump Open Error
Failure code [CA2266] Fuel Feed Pump Short Error
Failure code [CA2311] IMV Solenoid Error
Failure code [CA2555] Grid Htr Relay Volt High Error
Failure code [CA2556] Grid Htr Relay Volt Low Error
304 Troubleshooting by failure code (Display of code), Part 4
Failure code [D110KB] Battery relay drive: Short circuit
Failure code [D130KA] Neutral relay: Disconnection
Failure code [D130KB] Neutral relay: Short circuit
Failure code [D161KA] Back-up alarm relay: Disconnection
Failure code [D161KB] Back-up alarm relay: Short circuit
Failure code [D862KA] GPS Antenna Open Circuit
Failure code [DAFRKR] CAN Disconnection
Failure code [DAFRMC] CAN Discon (Monitor Detected)
Failure code [DB2RKR] CAN Disconnection
Failure code [DBE0KT] PT controller: Abnormality in controller
Failure code [DBE1KK] Battery direct Source voltage reduction
Failure code [DBE2KK] Solenoid Source voltage reduction
Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction
Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction
Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction
Failure code [DBE9KQ] PT controller: Type select signal
Failure code [DD12KA] Shift up Sw: Disconnection
Failure code [DD12KB] Shift up Sw: Short circuit
Failure code [DD13KA] Shift down Sw: Disconnection
Failure code [DD13KB] Shift down Sw: Short circuit
Failure code [DD14KA] Parking lever Sw: Disconnection
Failure code [DD14KB] Parking lever Sw: Short circuit
305 Troubleshooting by failure code (Display of code), Part 5
Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection
Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit
Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection
Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit
Failure code [DDNLKA] Weq lock Sw: Disconnection
Failure code [DDNLKB] Weq lock Sw: Short circuit
Failure code [DGS1KX] Hyd oil temp sensor: Abnormal
Failure code [DGT1KA] T/C oil temp sensor: Disconnection
Failure code [DGT1KX] T/C oil temp sensor: Short circuit
Failure code [DH21KA] Weq pressure sensor: Disconnection
Failure code [DH21KB] Weq pressure sensor: Short circuit
Failure code [DHT5KA] T/C pressure sensor: Disconnection
Failure code [DHT5KB] T/C pressure sensor: Short circuit
Failure code [DK10KA] Fuel control Dial: Disconnection
Failure code [DK10KB] Fuel control Dial: Short circuit
Failure code [DK30KA] ST lever 1: Disconnection
Failure code [DK30KB] ST lever 1: Short circuit
Failure code [DK30KX] ST lever: Out of normal range
Failure code [DK30KZ] ST lever: Disconnection or short circuit
Failure code [DK30L8] ST lever: Signal mismatch
Failure code [DK31KA] ST lever 2: Disconnection
Failure code [DK31KB] ST lever 2: Short circuit
Failure code [DK40KA] Brake potentiometer: Disconnection
Failure code [DK40KB] Brake potentiometer: Short circuit
Failure code [DK55KX] FR lever: Out of normal range
Failure code [DK55KZ] FR lever: Disconnection or short circuit
Failure code [DK55L8] FR lever: Signal mismatch
Failure code [DK56KA] FR lever 1: Disconnection
Failure code [DK56KB] FR lever 1: Short circuit
Failure code [DK57KA] FR lever 2: Disconnection
Failure code [DK57KB] FR lever 2: Short circuit
306 Troubleshooting by failure code (Display of code), Part 6
Failure code [DKH1KA] Pitch angle sensor: Disconnection
Failure code [DKH1KB] Pitch angle sensor: Short circuit
Failure code [DLT3KA] T/M out-speed sensor: Disconnection
Failure code [DLT3KB] T/M out-speed sensor: Abnormal
Failure code [DW5AKA] Pitch selector Sol.: Disconnection
Failure code [DW5AKB] Pitch selector Sol.: Short circuit
Failure code [DW5AKY] Pitch selector Sol.: Short circuit
Failure code [DW7BKA] Fan rev EPC: Disconnection
Failure code [DW7BKB] Fan rev EPC: Short circuit
Failure code [DWN1KA] Hss EPC1: Disconnection
Failure code [DWN1KB] Hss EPC1: Short circuit
Failure code [DWN1KY] Hss EPC1: Short circuit
Failure code [DWN2KA] Hss EPC2: Disconnection
Failure code [DWN2KB] Hss EPC2: Short circuit
Failure code [DWN2KY] Hss EPC2: Short circuit
Failure code [DWN5KA] Fan pump solenoid: Disconnection
Failure code [DWN5KB] Fan pump solenoid: Short circuit
Failure code [DWN5KY] Fan control solenoid: Short circuit
Failure code [DXA0KA] TVC Sol.: Disconnection
Failure code [DXA0KB] TVC Sol.: Short circuit
Failure code [DXA0KY] TVC Sol.: Short circuit
Failure code [DXH1KA] Lock-up ECMV: Disconnection
Failure code [DXH1KB] Lock-up ECMV: Short circuit
Failure code [DXH1KY] Lock-up ECMV: Short circuit
Failure code [DXH4KA] 1st clutch ECMV: Disconnection
Failure code [DXH4KB] 1st clutch ECMV: Short circuit
Failure code [DXH4KY] 1st clutch ECMV: Short circuit
Failure code [DXH5KA] 2nd clutch ECMV: Disconnection
Failure code [DXH5KB] 2nd clutch ECMV: Short circuit
Failure code [DXH5KY] 2nd clutch ECMV: Short circuit
Failure code [DXH6KA] 3rd clutch ECMV: Disconnection
Failure code [DXH6KB] 3rd clutch ECMV: Short circuit
Failure code [DXH6KY] 3rd clutch ECMV: Short circuit
Failure code [DXH7KA] R clutch ECMV: Disconnection
Failure code [DXH7KB] R clutch ECMV: Short circuit
Failure code [DXH7KY] R clutch ECMV: Short circuit
Failure code [DXH8KA] F clutch ECMV: Disconnection
Failure code [DXH8KB] F clutch ECMV: Short circuit
Failure code [DXH8KY] F clutch ECMV: Short circuit
Failure code [DXJ4KA] Weq lock Sol.: Disconnection
Failure code [DXJ4KB] Weq lock Sol.: Short circuit
400 Troubleshooting of electrical system (E-mode)
Before troubleshooting of electrical system
Information in troubleshooting table
E-1 Engine does not start (starting motor does not turn)
E-2 Preheater does not operate
E-3 When starting switch is turned ON, machine monitor displays nothing
E-4 When starting switch is turned ON (before starting engine), basic check item lights up
E-5 Precaution item lights up while engine is running
E-6 Emergency stop item lights up while engine is running
E-7 Engine coolant temperature gauge does not indicate normally
E-8 Fuel gauge does not indicate properly
E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally
E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally
E-11 Contents of display by machine monitor are different from applicable machine
E-12 Machine monitor does not display some items
E-13 Function switch does not work
E-14 Operation mode does not change
E-15 Gearshift mode does not change
E-16 Customize function does not operate normally
E-17 Customize memory function does not operate normally
E-18 Alarm buzzer does not sound or does not stop
E-19 When starting switch is turned OFF, service meter is not displayed
E-20 Machine monitor cannot be set in service mode
E-21 Horn does not sound or does not stop
E-22 Back-up alarm does not sound or does not stop
E-23 Head lamp or rear lamp does not light up
E-24 Windshield wiper does not operate
E-25 Window washer does not operate
E-26 KOMTRAX system does not operate correctly
500 Troubleshooting of hydraulic and mechanical system (H-mode)
Failure mode and cause table
Contents of troubleshooting table
H-1 There is no travel power (no drawbar pull).
H-2 Machine does not move (at 2nd or 3rd speed)
H-3 Machine does not move at any gear speed
H-4 Machine travels only in one direction, forward or in reverse
H-5 When gear is shifted or travel direction is changed, large time lag is made
H-6 Machine cannot be steered (Machine does not turn leftward or rightward)
H-7 Steering speed or power is low
H- 8 Brake does not work
H-9 Overheat of power train oil
H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor
H-11 All work equipment speeds are slow
H-12 Work equipment does not move
H-13 Blade lift speed is slow or lacks power
H-14 Blade tilt speed is slow or lacks power
H-15 Ripper lift speed is slow or lacks power
H-16 Excessive hydraulic drift of blade lift
H-17 Excessive hydraulic drift of blade tilt
H-18 Excessive hydraulic drift of ripper lift
600 Troubleshooting of engine (S-mode)
Method of using troubleshooting charts
S-1 Starting performance is poor.
S-2 Engine does not start
S-3 Engine does not pick up smoothly
S-4 Engine stops during operations
S-5 Engine does not rotate smoothly
S-6 Engine lacks output (or lacks power)
S-7 Exhaust smoke is black (incomplete combustion)
S-8 Oil consumption is excessive (or exhaust smoke is blue)
S-9 Oil becomes contaminated quickly
S-10 Fuel consumption is excessive
S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)
S-12 Oil pressure drops
S-13 Oil level rises (water, fuel in oil)
S-14 Coolant temperature becomes too high (overheating)
S-15 Abnormal noise is made
S-16 Vibration is excessive
50 Disassembly and assembly
100 General information on disassembly and assembly
How to read this manual
Coating materials list
Special tool list
Sketches of special tools
200 Engine and cooling system
Removal and installation of fuel supply pump assembly
Removal and installation of fuel injector assembly
Removal and installation of cylinder head assembly
Removal and installation of radiator assembly
Removal and installation of aftercooler assembly
Removal and installation of hydraulic oil cooler assembly
Removal and installation of power train oil cooler assembly
Removal and installation of cooling fan drive assembly
Removal and installation of cooling fan motor assembly
Removal and installation of main body of coolant preheater (subextremely cold weather spec)
Removal and installation of coolant preheater fuel tank (Subextremely cold weather spec.)
Removal and installation of coolant preheater exhaust duct. (Subextremely cold weather spec.)
Removal and installation of oil pan cover of coolant preheater (subextremely cold weather spec.)
Removal and installation of damper assembly
Removal and installation of engine front oil seal
Removal and installation of engine rear oil seal
Removal and installation of engine hood assembly
Removal and installation of fuel tank assembly
300 Power train
Removal and installation of power train unit assembly
Separation and connection of power train unit assembly
Disassembly and assembly of PTO assembly
Disassembly and assembly of torque converter assembly
Disassembly and assembly of transmission assembly
Disassembly and assembly of HSS assembly
Removal and installation of final drive assembly
Removal and installation of final drive assembly (Planetary gear installed inside of sprocket type)
Disassembly and assembly of final drive assembly
Disassembly and assembly of final drive assembly (Planetary gear installed inside of sprocket type)
400 Undercarriage and frame
Removal and installation of track frame assembly
Removal and installation of idler assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler assembly
Disassembly and assembly of idler assembly (Without idler support automatic thrust adjustment)
Removal and installation of recoil spring assembly
Disassembly and assembly of recoil spring assembly
Removal and installation of track roller assembly
Disassembly and assembly of track roller assembly
Removal and installation of carrier roller assembly
Disassembly and assembly of carrier roller assembly
Expansion and installation of track shoe assembly (Conventional type track shoe)
Expansion and installation of track shoe assembly (PLUS type track shoe)
Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe)
Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe)
Field disassembly and assembly of one link (Conventional type track shoe)
Field disassembly and assembly of one link (PLUS type track shoe)
Removal and installation of pivot shaft assembly
Removal and installation of equalizer bar assembly
Disassembly and assembly of equalizer bar side bushing
500 Hydraulic system
Removal and installation of hydraulic tank assembly
Removal and installation of control valve assembly
Disassembly and assembly of control valve assembly
Disassembly and assembly of blade lift and tilt PPC valve assembly
Disassembly and assembly of ripper PPC valve assembly
Removal and installation of HSS and cooling fan pump assembly
Removal and installation of power train and lubrication pump assembly
Removal and installation of scavenging pump assembly
Removal and installation of HSS motor assembly
Disassembly and assembly of hydraulic cylinder assembly
600 Work equipment
Removal and installation of blade assembly (ST-TPP dozer)
Removal and installation of blade assembly (PAT dozer)
Removal and installation of ripper assembly
700 Cab and its attachments
Removal and installation of ROPS cab assembly
Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of floor frame assembly (FRP canopy specification)
Removal and installation of operator’s cab glass (Stuck glass)
Removal and installation of air conditioner unit assembly
Removal and installation of air conditioner compressor assembly
800 Electrical system
Removal and installation of monitor panel assembly
Removal and installation of engine controller assembly
Removal and installation of power train controller assembly
Removal and installation of KOMTRAX terminal assembly
80 Appendix
100 Air conditioner
Structure and function
Air conditioner component
Configuration and function of refrigerating cycle
Outline of refrigerating cycle
Air conditioner unit
Control plate
Compressor
Condenser
Receiver drier
Testing, adjusting and troubleshooting
Caution about refrigerant
Troubleshooting procedure
Block diagram
Circuit diagram and arrangement of connector pins
Detail of air conditioner unit
Parts and connectors arrangement
Testing air leakage (duct)
Testing with self-diagnosis function
Testing temperature control
Testing vent (mode) changeover
Testing Recirc/Fresh changeover
Testing inner sensor
Testing evaporator temperature sensor
Testing sunlight sensor
Testing (dual) pressure switch for refrigerant
Testing relays and diodes
Troubleshooting chart 1
Troubleshooting chart 2
Troubleshooting for electrical system (E mode)
E-1 Power supply system (Air conditioner does not operate)
E-2 Compressor and refrigerant system (Air is not cooled)
E-3 Blower motor system (No air comes out or air flow is abnormal)
E-4 Temperature cannot be controlled
E-5 Vent (mode) cannot be changed over
E-6 Recirc/Fresh air cannot be changed over
Troubleshooting with gauge pressure
Connection of service tool
Precautions for connecting air conditioner piping
Handling of compressor oil
1. Control of compressor oil (Denso: ND-OIL8: For R134a)
2. Adding of compressor oil
3. Compressor replacement
4. Applying compressor oil for O-ring
90 Diagrams and drawings
100 Hydraulic diagrams and drawings
Power train hydraulic circuit diagram
Work equipment hydraulic circuit diagram
200 Electrical diagrams and drawings
Electrical circuit diagram
Electrical circuit diagram (Sand terrain specification)
Electrical circuit diagram (FRP canopy specification)
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