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Komatsu d65 wx 16 dozer bulldozer service repair manual sn 80001 and up

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service repair workshop manual

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BULLDOZER SEN04887-05 D65EX -16 D65PX -16 D65WX-16 SERIAL NUMBERS D65EX- 80001 D65PX- 80001 D65WX-80001 and up
SEN04931-05 00-100 4 D65EX, PX, WX-16 Table of contents 100 Index Table of contents 1 00 Index and foreword 100 Index ..........................................................................................................................................SEN04931-05 Composition of shop manual......................................................................................................................... 2 Table of contents........................................................................................................................................... 4 200 Foreword and general information.............................................................................................SEN04932-01 Safety notice ................................................................................................................................................. 2 How to read the shop manual ....................................................................................................................... 7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 General 100 Specification and technical data.................................................................................................SEN04933-00 Specification dimension drawing................................................................................................................... 2 Specifications ................................................................................................................................................ 6 Weight table .................................................................................................................................................. 18 Table of fuel, coolant and lubricants.............................................................................................................. 22 10 Structure, function and maintenance standard 100 Engine and cooling system........................................................................................................SEN04963-00 Engine mount................................................................................................................................................ 3 Cooling system.............................................................................................................................................. 4 Cooling fan pump.......................................................................................................................................... 6 Cooling fan motor.......................................................................................................................................... 20 201 Power train, Part 1 .....................................................................................................................SEN04964-00 Power train.................................................................................................................................................... 2 HSS system .................................................................................................................................................. 4 Overall view of power train unit..................................................................................................................... 6 Power train hydraulic piping diagram............................................................................................................ 10 Transmission, steering and brake control ..................................................................................................... 12 Damper ......................................................................................................................................................... 14 Universal joint................................................................................................................................................ 16 Torque converter and PTO............................................................................................................................ 17 Transmission................................................................................................................................................. 24 Transmission control valve............................................................................................................................ 42 ECMV............................................................................................................................................................ 46 Main relief and torque converter relief valve ................................................................................................. 54 Transmission lubrication relief valve ............................................................................................................. 56 202 Power train, Part 2 .....................................................................................................................SEN04965-00 Bevel gear shaft, HSS and brake.................................................................................................................. 2 Brake valve ................................................................................................................................................... 24 Final drive...................................................................................................................................................... 30 300 Undercarriage and frame...........................................................................................................SEN04966-01 Main frame .................................................................................................................................................... 2 Suspension ................................................................................................................................................... 4 Track frame and idler cushion....................................................................................................................... 14 Idler ............................................................................................................................................................... 18 Track roller .................................................................................................................................................... 20 Carrier roller .................................................................................................................................................. 24 Sprocket ........................................................................................................................................................ 26
SEN04931-05 D65EX, PX, WX-16 00-100 5 Table of contents 100 Index Track shoe..................................................................................................................................................... 30 401 Hydraulic system, Part 1 ........................................................................................................... SEN04967-00 Work equipment hydraulic system layout drawing ........................................................................................ 2 Work equipment control................................................................................................................................. 6 Hydraulic tank and filter ................................................................................................................................. 8 Scavenging pump.......................................................................................................................................... 10 Power train and steering lubrication pump .................................................................................................... 11 HSS pump ..................................................................................................................................................... 12 HSS motor..................................................................................................................................................... 31 402 Hydraulic system, Part 2 ........................................................................................................... SEN04968-01 Control valve.................................................................................................................................................. 2 CLSS ............................................................................................................................................................. 11 Function and operation of each valve............................................................................................................ 14 403 Hydraulic system, Part 3 ........................................................................................................... SEN04969-00 PPC valve (blade lift, blade tilt)...................................................................................................................... 2 PPC valve (ripper) ......................................................................................................................................... 8 Electric lever (steering).................................................................................................................................. 12 Quick drop valve............................................................................................................................................ 16 Work equipment lock solenoid valve ............................................................................................................. 18 Pitch selector solenoid valve ......................................................................................................................... 22 Hydraulic oil cooler bypass valve .................................................................................................................. 23 Accumulator................................................................................................................................................... 24 500 Work equipment ........................................................................................................................ SEN04970-00 Blade ............................................................................................................................................................. 2 Cutting edge and end bit ............................................................................................................................... 8 Ripper............................................................................................................................................................ 10 Hydraulic cylinder .......................................................................................................................................... 11 Piston valve ................................................................................................................................................... 14 600 Cab and its attachments............................................................................................................ SEN04971-00 Cab mount..................................................................................................................................................... 2 Cab................................................................................................................................................................ 3 700 Electrical system ....................................................................................................................... SEN04972-00 Monitor system .............................................................................................................................................. 2 Engine control system ................................................................................................................................... 18 Cooling system control system...................................................................................................................... 21 Electronic steering control system................................................................................................................. 23 KOMTRAX system ........................................................................................................................................ 26 System components...................................................................................................................................... 28 Sensor ........................................................................................................................................................... 36 20 Standard value table 100 Standard service value table ..................................................................................................... SEN05118-01 Standard service value table for engine ........................................................................................................ 2 Standard service value table for chassis ....................................................................................................... 4 30 Testing and adjusting 101 Testing and adjusting, Part 1..................................................................................................... SEN05119-02 Tools for testing, adjusting, and troubleshooting ........................................................................................... 2 Testing engine speed..................................................................................................................................... 5 Testing intake air pressure (boost pressure) ................................................................................................. 7 Testing exhaust temperature ......................................................................................................................... 9 Testing exhaust gas color.............................................................................................................................. 11 Adjusting valve clearance.............................................................................................................................. 12 Testing compression pressure....................................................................................................................... 14 Testing blow-by pressure............................................................................................................................... 18 Testing engine oil pressure............................................................................................................................ 19
SEN04931-05 00-100 6 D65EX, PX, WX-16 Table of contents 100 Index Handling of fuel system devices.................................................................................................................... 20 Releasing residual pressure from fuel system .............................................................................................. 20 Testing fuel pressure..................................................................................................................................... 21 Testing fuel return and leak amount.............................................................................................................. 26 Bleeding air from fuel circuit.......................................................................................................................... 28 Testing fuel circuit for leakage....................................................................................................................... 29 Handling of reduced cylinder mode operation............................................................................................... 30 Handling of no injection cranking operation .................................................................................................. 30 Testing and adjusting air conditioner compressor belt tension...................................................................... 31 Replacing alternator belt ............................................................................................................................... 32 Adjusting fuel control dial and decelerator pedal .......................................................................................... 33 Handling controller high-voltage circuit ......................................................................................................... 34 102 Testing and adjusting, Part 2......................................................................................................SEN05120-01 Testing power train oil pressure .................................................................................................................... 3 Adjusting transmission output shaft speed sensor (replacement procedure) ............................................... 8 Simple test procedure for brake performance............................................................................................... 9 Adjusting brake pedal.................................................................................................................................... 10 Adjusting parking brake lever........................................................................................................................ 12 Emergency escape method when power train has trouble ........................................................................... 14 Adjusting clearance of idler........................................................................................................................... 17 Inspecting wear of sprocket .......................................................................................................................... 18 Testing and adjusting track shoe tension ...................................................................................................... 19 Testing and adjusting work equipment and HSS oil pressure....................................................................... 20 Testing control circuit basic pressure ............................................................................................................ 23 Testing PPC valve output pressure............................................................................................................... 24 Adjusting work equipment PPC valve play.................................................................................................... 26 Testing internal leakage of work equipment cylinder..................................................................................... 30 Bleeding air from work equipment cylinder ................................................................................................... 31 Releasing residual pressure from work equipment cylinder.......................................................................... 31 Checking parts which caused hydraulic drift of blade or ripper..................................................................... 32 Adjusting work equipment lock lever............................................................................................................. 33 Testing fan speed.......................................................................................................................................... 34 Testing fan circuit oil pressure....................................................................................................................... 35 Bleeding air from fan pump........................................................................................................................... 36 Bleeding air from HSS pump......................................................................................................................... 37 Adjusting straight tiltdozer............................................................................................................................. 38 Adjusting play of blade center ball ................................................................................................................ 40 Adjusting operator’s cab................................................................................................................................ 41 103 Testing and adjusting, Part 3......................................................................................................SEN05121-02 Special functions of machine monitor (EMMS) ............................................................................................. 2 104 Testing and adjusting, Part 4......................................................................................................SEN05122-01 Handling of voltage circuit of engine controller ............................................................................................. 2 Adjustment method when controller has been replaced ............................................................................... 3 Preparation work for troubleshooting of electrical system............................................................................. 5 Inspection procedure of diode....................................................................................................................... 9 Pm-Clinic service .......................................................................................................................................... 10 40 Troubleshooting 100 Failure code table and fuse locations ........................................................................................SEN05029-01 Failure codes table........................................................................................................................................ 2 Fuse locations............................................................................................................................................... 7 200 General information on troubleshooting.....................................................................................SEN05030-01 Points to remember when troubleshooting.................................................................................................... 2 How to proceed troubleshooting ................................................................................................................... 3 Checks before troubleshooting ..................................................................................................................... 4 Classification and procedures for troubleshooting ........................................................................................ 6 Symptom supposed to be failure and troubleshooting No. ........................................................................... 10
SEN04931-05 D65EX, PX, WX-16 00-100 7 Table of contents 100 Index Information contained in troubleshooting table.............................................................................................. 12 Troubleshooting method for disconnecting wiring harness of pressure sensor system ................................ 14 Connector list and stereogram ...................................................................................................................... 16 Connection table for connector pin numbers................................................................................................. 30 T- branch box and T- branch adapter table ................................................................................................... 66 301 Troubleshooting by failure code (Display of code), Part 1......................................................... SEN05031-00 Failure code [1500L0] Transmission clutch: Abnormal.................................................................................. 3 Failure code [15SAL1] Forward clutch: Fill high............................................................................................ 4 Failure code [15SALH] Forward clutch: Fill low............................................................................................. 6 Failure code [15SBL1] Reverse clutch: Fill high............................................................................................ 8 Failure code [15SBLH] Reverse clutch: Fill low............................................................................................. 10 Failure code [15SEL1] Speed 1st clutch: Fill high ......................................................................................... 12 Failure code [15SELH] Speed 1st clutch: Fill low.......................................................................................... 14 Failure code [15SFL1] Speed 2nd clutch: Fill high ........................................................................................ 16 Failure code [15SFLH] Speed 2nd clutch: Fill low......................................................................................... 18 Failure code [15SGL1] Speed 3rd clutch: Fill high ........................................................................................ 20 Failure code [15SGLH] Speed 3rd clutch: Fill low ......................................................................................... 22 Failure code [15SJL1] L/U: Fill high............................................................................................................... 24 Failure code [15SJLH] L/U: Fill low ............................................................................................................... 26 Failure code [AB00MA] Battery Charge Abnormal........................................................................................ 28 Failure code [B@BAZG] Eng Oil Press Low ................................................................................................. 30 Failure code [B@BCNS] Eng Water Overheat .............................................................................................. 30 Failure code [B@CENS] T/C Oil Overheat.................................................................................................... 31 Failure code [B@HANS] Hyd Oil Overheat ................................................................................................... 31 302 Troubleshooting by failure code (Display of code), Part 2......................................................... SEN05032-01 Failure code [CA111] ECM Critical Internal Failure ....................................................................................... 3 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 3 Failure code [CA122] Chg Air Press Sensor High Error................................................................................ 4 Failure code [CA123] Chg Air Press Sensor Low Error................................................................................. 6 Failure code [CA131] Throttle Sensor High Error.......................................................................................... 8 Failure code [CA132] Throttle Sensor Low Error........................................................................................... 10 Failure code [CA144] Coolant Temp Sens High Error................................................................................... 12 Failure code [CA145] Coolant Temp Sens Low Error.................................................................................... 14 Failure code [CA153] Chg Air Temp Sensor High Error ................................................................................ 16 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................. 18 Failure code [CA155] Chg Air Temp High Speed Derate............................................................................... 20 Failure code [CA187] Sens Supply 2 Volt Low Error..................................................................................... 22 Failure code [CA221] Ambient Press Sens High Error.................................................................................. 24 Failure code [CA222] Ambient Press Sens Low Error................................................................................... 26 Failure code [CA227] Sens Supply 2 Volt High Error .................................................................................... 28 Failure code [CA234] Eng Overspeed........................................................................................................... 28 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................... 29 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 30 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................ 32 Failure code [CA281] Abnormal supply pump pressure balance .................................................................. 34 Failure code [CA322] Inj #1(L#1) Open/Short Error ...................................................................................... 36 Failure code [CA323] Inj #5(L#5) Open/Short Error ...................................................................................... 38 Failure code [CA324] Inj #3(L#3) Open/Short Error ...................................................................................... 40 Failure code [CA325] Inj #6(L#6) Open/Short Error ...................................................................................... 42 Failure code [CA331] Inj #2(L#2) Open/Short Error ...................................................................................... 44 Failure code [CA332] Inj #4(L#4) Open/Short Error ...................................................................................... 46 303 Troubleshooting by failure code (Display of code), Part 3......................................................... SEN05033-01 Failure code [CA342] Calibration Code Incompatibility ................................................................................. 3 Failure code [CA351] Injectors Drive Circuit Error......................................................................................... 3 Failure code [CA352] Sens Supply 1 Volt Low Error..................................................................................... 4 Failure code [CA386] Sens Supply 1 Volt High Error .................................................................................... 6 Failure code [CA428] Water in Fuel Sensor High Error................................................................................. 8 Failure code [CA429] Water in Fuel Sensor Low Error.................................................................................. 10
SEN04931-05 00-100 8 D65EX, PX, WX-16 Table of contents 100 Index Failure code [CA435] Eng Oil Press Sw Error .............................................................................................. 12 Failure code [CA441] Battery Voltage Low Error .......................................................................................... 14 Failure code [CA442] Battery Voltage High Error.......................................................................................... 16 Failure code [CA449] Rail Press Very High Error ......................................................................................... 18 Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 20 Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 22 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................. 24 Failure code [CA553] Rail Press High Error.................................................................................................. 25 Failure code [CA559] Rail Press Low Error .................................................................................................. 26 Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 28 Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 32 Failure code [CA757] All Continuous Data Lost Error................................................................................... 33 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 34 Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 37 Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................ 38 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 40 Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 42 Failure code [CA2265] Fuel Feed Pump Open Error.................................................................................... 44 Failure code [CA2266] Fuel Feed Pump Short Error .................................................................................... 46 Failure code [CA2311] IMV Solenoid Error ................................................................................................... 47 Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 48 Failure code [CA2556] Grid Htr Relay Volt Low Error................................................................................... 50 304 Troubleshooting by failure code (Display of code), Part 4 .........................................................SEN05034-01 Failure code [D110KB] Battery relay drive: Short circuit ............................................................................... 4 Failure code [D130KA] Neutral relay: Disconnection.................................................................................... 6 Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 8 Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 10 Failure code [D161KB] Back-up alarm relay: Short circuit............................................................................ 12 Failure code [D862KA] GPS Antenna Open Circuit...................................................................................... 14 Failure code [DAFRKR] CAN Disconnection ................................................................................................ 15 Failure code [DAFRMC] CAN Discon (Monitor Detected)............................................................................. 16 Failure code [DB2RKR] CAN Disconnection................................................................................................. 19 Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 24 Failure code [DBE1KK] Battery direct Source voltage reduction .................................................................. 26 Failure code [DBE2KK] Solenoid Source voltage reduction ......................................................................... 28 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction .............................................................. 30 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction.................................................................. 32 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction .............................................................. 34 Failure code [DBE9KQ] PT controller: Type select signal............................................................................. 36 Failure code [DD12KA] Shift up Sw: Disconnection...................................................................................... 38 Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 40 Failure code [DD13KA] Shift down Sw: Disconnection................................................................................. 42 Failure code [DD13KB] Shift down Sw: Short circuit..................................................................................... 44 Failure code [DD14KA] Parking lever Sw: Disconnection............................................................................. 46 Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 48 305 Troubleshooting by failure code (Display of code), Part 5 .........................................................SEN05035-00 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ................................................................... 4 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit....................................................................... 6 Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection........................................................................ 8 Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit ........................................................................... 10 Failure code [DDNLKA] Weq lock Sw: Disconnection .................................................................................. 12 Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................... 14 Failure code [DGS1KX] Hyd oil temp sensor: Abnormal............................................................................... 16 Failure code [DGT1KA] T/C oil temp sensor: Disconnection ........................................................................ 18 Failure code [DGT1KX] T/C oil temp sensor: Short circuit ............................................................................ 20 Failure code [DH21KA] Weq pressure sensor: Disconnection...................................................................... 22 Failure code [DH21KB] Weq pressure sensor: Short circuit ......................................................................... 24 Failure code [DHT5KA] T/C pressure sensor: Disconnection....................................................................... 26
SEN04931-05 D65EX, PX, WX-16 00-100 9 Table of contents 100 Index Failure code [DHT5KB] T/C pressure sensor: Short circuit........................................................................... 28 Failure code [DK10KA] Fuel control Dial: Disconnection .............................................................................. 30 Failure code [DK10KB] Fuel control Dial: Short circuit.................................................................................. 32 Failure code [DK30KA] ST lever 1: Disconnection........................................................................................ 34 Failure code [DK30KB] ST lever 1: Short circuit............................................................................................ 36 Failure code [DK30KX] ST lever: Out of normal range.................................................................................. 38 Failure code [DK30KZ] ST lever: Disconnection or short circuit.................................................................... 38 Failure code [DK30L8] ST lever: Signal mismatch........................................................................................ 39 Failure code [DK31KA] ST lever 2: Disconnection........................................................................................ 40 Failure code [DK31KB] ST lever 2: Short circuit............................................................................................ 42 Failure code [DK40KA] Brake potentiometer: Disconnection........................................................................ 44 Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................ 46 Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 48 Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 48 Failure code [DK55L8] FR lever: Signal mismatch........................................................................................ 49 Failure code [DK56KA] FR lever 1: Disconnection........................................................................................ 50 Failure code [DK56KB] FR lever 1: Short circuit ........................................................................................... 52 Failure code [DK57KA] FR lever 2: Disconnection........................................................................................ 54 Failure code [DK57KB] FR lever 2: Short circuit ........................................................................................... 56 306 Troubleshooting by failure code (Display of code), Part 6......................................................... SEN05036-01 Failure code [DKH1KA] Pitch angle sensor: Disconnection .......................................................................... 4 Failure code [DKH1KB] Pitch angle sensor: Short circuit.............................................................................. 6 Failure code [DLT3KA] T/M out-speed sensor: Disconnection...................................................................... 8 Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................. 9 Failure code [DW5AKA] Pitch selector Sol.: Disconnection .......................................................................... 10 Failure code [DW5AKB] Pitch selector Sol.: Short circuit.............................................................................. 11 Failure code [DW5AKY] Pitch selector Sol.: Short circuit.............................................................................. 12 Failure code [DW7BKA] Fan rev EPC: Disconnection .................................................................................. 14 Failure code [DW7BKB] Fan rev EPC: Short circuit...................................................................................... 15 Failure code [DWN1KA] Hss EPC1: Disconnection ...................................................................................... 16 Failure code [DWN1KB] Hss EPC1: Short circuit.......................................................................................... 17 Failure code [DWN1KY] Hss EPC1: Short circuit.......................................................................................... 18 Failure code [DWN2KA] Hss EPC2: Disconnection ...................................................................................... 19 Failure code [DWN2KB] Hss EPC2: Short circuit.......................................................................................... 20 Failure code [DWN2KY] Hss EPC2: Short circuit.......................................................................................... 21 Failure code [DWN5KA] Fan pump solenoid: Disconnection ........................................................................ 22 Failure code [DWN5KB] Fan pump solenoid: Short circuit............................................................................ 23 Failure code [DWN5KY] Fan control solenoid: Short circuit.......................................................................... 24 Failure code [DXA0KA] TVC Sol.: Disconnection.......................................................................................... 26 Failure code [DXA0KB] TVC Sol.: Short circuit ............................................................................................. 27 Failure code [DXA0KY] TVC Sol.: Short circuit ............................................................................................. 28 Failure code [DXH1KA] Lock-up ECMV: Disconnection................................................................................ 29 Failure code [DXH1KB] Lock-up ECMV: Short circuit ................................................................................... 30 Failure code [DXH1KY] Lock-up ECMV: Short circuit ................................................................................... 32 Failure code [DXH4KA] 1st clutch ECMV: Disconnection ............................................................................. 34 Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................................................. 35 Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................................................. 36 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ............................................................................ 37 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit................................................................................ 38 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit................................................................................ 39 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection............................................................................. 40 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................. 41 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit................................................................................. 42 Failure code [DXH7KA] R clutch ECMV: Disconnection................................................................................ 43 Failure code [DXH7KB] R clutch ECMV: Short circuit ................................................................................... 44 Failure code [DXH7KY] R clutch ECMV: Short circuit ................................................................................... 46 Failure code [DXH8KA] F clutch ECMV: Disconnection................................................................................ 48 Failure code [DXH8KB] F clutch ECMV: Short circuit.................................................................................... 49
SEN04931-05 00-100 10 D65EX, PX, WX-16 Table of contents 100 Index Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................................... 50 Failure code [DXJ4KA] Weq lock Sol.: Disconnection .................................................................................. 52 Failure code [DXJ4KB] Weq lock Sol.: Short circuit...................................................................................... 53 400 Troubleshooting of electrical system (E-mode)..........................................................................SEN05037-01 Before troubleshooting of electrical system .................................................................................................. 3 Information in troubleshooting table.............................................................................................................. 5 E-1 Engine does not start (starting motor does not turn) .............................................................................. 7 E-2 Preheater does not operate.................................................................................................................... 10 E-3 When starting switch is turned ON, machine monitor displays nothing.................................................. 16 E-4 When starting switch is turned ON (before starting engine), basic check item lights up ........................ 18 E-5 Precaution item lights up while engine is running................................................................................... 20 E-6 Emergency stop item lights up while engine is running.......................................................................... 22 E-7 Engine coolant temperature gauge does not indicate normally.............................................................. 24 E-8 Fuel gauge does not indicate properly ................................................................................................... 26 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 29 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 30 E-11 Contents of display by machine monitor are different from applicable machine................................... 31 E-12 Machine monitor does not display some items..................................................................................... 31 E-13 Function switch does not work ............................................................................................................. 31 E-14 Operation mode does not change ........................................................................................................ 32 E-15 Gearshift mode does not change ......................................................................................................... 32 E-16 Customize function does not operate normally .................................................................................... 33 E-17 Customize memory function does not operate normally ...................................................................... 33 E-18 Alarm buzzer does not sound or does not stop.................................................................................... 34 E-19 When starting switch is turned OFF, service meter is not displayed .................................................... 34 E-20 Machine monitor cannot be set in service mode .................................................................................. 34 E-21 Horn does not sound or does not stop ................................................................................................. 35 E-22 Back-up alarm does not sound or does not stop.................................................................................. 36 E-23 Head lamp or rear lamp does not light up ............................................................................................ 38 E-24 Windshield wiper does not operate ...................................................................................................... 42 E-25 Window washer does not operate ........................................................................................................ 56 E-26 KOMTRAX system does not operate correctly..................................................................................... 61 500 Troubleshooting of hydraulic and mechanical system (H-mode) ...............................................SEN05038-00 Failure mode and cause table....................................................................................................................... 2 Contents of troubleshooting table ................................................................................................................. 4 H-1 There is no travel power (no drawbar pull)............................................................................................. 5 H-2 Machine does not move (at 2nd or 3rd speed)....................................................................................... 6 H-3 Machine does not move at any gear speed ........................................................................................... 7 H-4 Machine travels only in one direction, forward or in reverse .................................................................. 8 H-5 When gear is shifted or travel direction is changed, large time lag is made .......................................... 9 H-6 Machine cannot be steered (Machine does not turn leftward or rightward) ........................................... 10 H-7 Steering speed or power is low .............................................................................................................. 10 H- 8 Brake does not work.............................................................................................................................. 11 H-9 Overheat of power train oil ..................................................................................................................... 12 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor................... 13 H-11 All work equipment speeds are slow .................................................................................................... 13 H-12 Work equipment does not move........................................................................................................... 14 H-13 Blade lift speed is slow or lacks power................................................................................................. 14 H-14 Blade tilt speed is slow or lacks power................................................................................................. 15 H-15 Ripper lift speed is slow or lacks power ............................................................................................... 15 H-16 Excessive hydraulic drift of blade lift..................................................................................................... 16 H-17 Excessive hydraulic drift of blade tilt .................................................................................................... 16 H-18 Excessive hydraulic drift of ripper lift .................................................................................................... 17 600 Troubleshooting of engine (S-mode)..........................................................................................SEN05039-00 Method of using troubleshooting charts ........................................................................................................ 3 S-1 Starting performance is poor................................................................................................................... 6 S-2 Engine does not start.............................................................................................................................. 7 S-3 Engine does not pick up smoothly.......................................................................................................... 10
SEN04931-05 D65EX, PX, WX-16 00-100 11 Table of contents 100 Index S-4 Engine stops during operations .............................................................................................................. 11 S-5 Engine does not rotate smoothly ............................................................................................................ 12 S-6 Engine lacks output (or lacks power)...................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion) .................................................................................. 14 S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................................... 15 S-9 Oil becomes contaminated quickly ......................................................................................................... 16 S-10 Fuel consumption is excessive ............................................................................................................. 17 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)................................................... 18 S-12 Oil pressure drops................................................................................................................................. 19 S-13 Oil level rises (water, fuel in oil) ............................................................................................................ 20 S-14 Coolant temperature becomes too high (overheating).......................................................................... 21 S-15 Abnormal noise is made ....................................................................................................................... 22 S-16 Vibration is excessive ........................................................................................................................... 23 50 Disassembly and assembly 100 General information on disassembly and assembly.................................................................. SEN05110-00 How to read this manual................................................................................................................................ 2 Coating materials list ..................................................................................................................................... 4 Special tool list............................................................................................................................................... 7 Sketches of special tools............................................................................................................................... 16 200 Engine and cooling system ........................................................................................................SEN05111-00 Removal and installation of fuel supply pump assembly............................................................................... 2 Removal and installation of fuel injector assembly........................................................................................ 7 Removal and installation of cylinder head assembly..................................................................................... 17 Removal and installation of radiator assembly.............................................................................................. 32 Removal and installation of aftercooler assembly ......................................................................................... 35 Removal and installation of hydraulic oil cooler assembly ............................................................................ 37 Removal and installation of power train oil cooler assembly......................................................................... 39 Removal and installation of cooling fan drive assembly................................................................................ 42 Removal and installation of cooling fan motor assembly............................................................................... 44 Removal and installation of engine assembly ............................................................................................... 46 Removal and installation of damper assembly.............................................................................................. 54 Removal and installation of engine front oil seal ........................................................................................... 57 Removal and installation of engine rear oil seal............................................................................................ 61 Removal and installation of engine hood assembly ...................................................................................... 69 Removal and installation of fuel tank assembly............................................................................................. 71 300 Power train ................................................................................................................................ SEN05112-00 Removal and installation of power train unit assembly.................................................................................. 2 Separation and connection of power train unit assembly.............................................................................. 6 Disassembly and assembly of PTO assembly............................................................................................... 11 Disassembly and assembly of torque converter assembly............................................................................ 16 Disassembly and assembly of transmission assembly.................................................................................. 27 Disassembly and assembly of HSS assembly .............................................................................................. 54 Removal and installation of final drive assembly........................................................................................... 74 Disassembly and assembly of final drive assembly ...................................................................................... 76 400 Undercarriage and frame .......................................................................................................... SEN05113-01 Removal and installation of track frame assembly ........................................................................................ 2 Removal and installation of idler assembly ................................................................................................... 4 Disassembly and assembly of idler assembly............................................................................................... 6 Removal and installation of recoil spring assembly....................................................................................... 10 Disassembly and assembly of recoil spring assembly .................................................................................. 11 Removal and installation of track roller assembly ......................................................................................... 15 Disassembly and assembly of track roller assembly..................................................................................... 16 Removal and installation of carrier roller assembly ....................................................................................... 20 Disassembly and assembly of carrier roller assembly................................................................................... 21 Expansion and installation of track shoe assembly (Conventional type track shoe) ..................................... 24 Expansion and installation of track shoe assembly (PLUS type track shoe)................................................. 27
SEN04931-05 00-100 12 D65EX, PX, WX-16 Table of contents 100 Index Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe).............. 28 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe).......................... 42 Field disassembly and assembly of one link (Conventional type track shoe) ............................................... 54 Field disassembly and assembly of one link (PLUS type track shoe)........................................................... 61 Removal and installation of pivot shaft assembly.......................................................................................... 66 Removal and installation of equalizer bar assembly..................................................................................... 67 Disassembly and assembly of equalizer bar side bushing............................................................................ 69 500 Hydraulic system........................................................................................................................SEN05114-00 Removal and installation of hydraulic tank assembly.................................................................................... 2 Removal and installation of control valve assembly...................................................................................... 5 Disassembly and assembly of control valve assembly ................................................................................. 8 Disassembly and assembly of blade lift and tilt PPC valve assembly........................................................... 10 Disassembly and assembly of ripper PPC valve assembly .......................................................................... 11 Removal and installation of HSS and cooling fan pump assembly............................................................... 12 Removal and installation of power train and lubrication pump assembly...................................................... 14 Removal and installation of scavenging pump assembly.............................................................................. 16 Removal and installation of HSS motor assembly ........................................................................................ 17 Disassembly and assembly of hydraulic cylinder assembly.......................................................................... 20 600 Work equipment.........................................................................................................................SEN05115-00 Removal and installation of blade assembly (ST-TPP dozer) ....................................................................... 2 Removal and installation of blade assembly (PAT dozer) ............................................................................. 5 Removal and installation of ripper assembly................................................................................................. 7 700 Cab and its attachments ............................................................................................................SEN05116-00 Removal and installation of ROPS cab assembly......................................................................................... 2 Removal and installation of operator’s cab glass (Stuck glass) .................................................................... 9 Removal and installation of air conditioner unit assembly ............................................................................ 15 Removal and installation of air conditioner compressor assembly ............................................................... 19 800 Electrical system........................................................................................................................SEN05117-00 Removal and installation of monitor panel assembly .................................................................................... 2 Removal and installation of engine controller assembly ............................................................................... 4 Removal and installation of power train controller assembly ........................................................................ 6 Removal and installation of KOMTRAX terminal assembly .......................................................................... 8 80 Appendix 100 Air conditioner............................................................................................................................SEN05041-00 Structure and function....................................................................................................................................... 4 Air conditioner component ............................................................................................................................ 4 Configuration and function of refrigerating cycle........................................................................................... 6 Outline of refrigerating cycle ......................................................................................................................... 7 Air conditioner unit ........................................................................................................................................ 10 Control plate.................................................................................................................................................. 14 Compressor................................................................................................................................................... 15 Condenser..................................................................................................................................................... 16 Receiver drier................................................................................................................................................ 17 Testing, adjusting and troubleshooting ............................................................................................................. 18 Caution about refrigerant .............................................................................................................................. 18 Troubleshooting procedure ........................................................................................................................... 19 Block diagram ............................................................................................................................................... 20 Circuit diagram and arrangement of connector pins ..................................................................................... 22 Detail of air conditioner unit........................................................................................................................... 24 Parts and connectors arrangement............................................................................................................... 26 Testing air leakage (duct).............................................................................................................................. 32 Testing with self-diagnosis function............................................................................................................... 34 Testing temperature control........................................................................................................................... 37 Testing vent (mode) changeover................................................................................................................... 39 Testing Recirc/Fresh changeover.................................................................................................................. 42 Testing inner sensor...................................................................................................................................... 43
SEN04931-05 D65EX, PX, WX-16 00-100 13 Table of contents 100 Index Testing evaporator temperature sensor......................................................................................................... 44 Testing sunlight sensor.................................................................................................................................. 47 Testing (dual) pressure switch for refrigerant ................................................................................................ 48 Testing relays and diodes.............................................................................................................................. 50 Troubleshooting chart 1................................................................................................................................. 52 Troubleshooting chart 2................................................................................................................................. 53 Troubleshooting for electrical system (E mode) ............................................................................................ 56 E-1 Power supply system (Air conditioner does not operate)..................................................................... 57 E-2 Compressor and refrigerant system (Air is not cooled)........................................................................ 60 E-3 Blower motor system (No air comes out or air flow is abnormal)......................................................... 63 E-4 Temperature cannot be controlled ....................................................................................................... 66 E-5 Vent (mode) cannot be changed over.................................................................................................. 68 E-6 Recirc/Fresh air cannot be changed over............................................................................................ 70 Troubleshooting with gauge pressure............................................................................................................ 72 Connection of service tool ............................................................................................................................. 75 Precautions for connecting air conditioner piping.......................................................................................... 76 Handling of compressor oil............................................................................................................................ 77 1. Control of compressor oil (Denso: ND-OIL8: For R134a)..................................................................... 77 2. Adding of compressor oil ...................................................................................................................... 77 3. Compressor replacement ..................................................................................................................... 78 4. Applying compressor oil for O-ring ....................................................................................................... 78 90 Diagrams and drawings 100 Hydraulic diagrams and drawings ............................................................................................. SEN04934-00 Power train hydraulic circuit diagram............................................................................................................. 3 Work equipment hydraulic circuit diagram..................................................................................................... 5 200 Electrical diagrams and drawings.............................................................................................. SEN04935-00 Electrical circuit diagram................................................................................................................................ 3
SEN04932-01 00-200 2 D65EX, PX, WX-16 200 Foreword and general information Safety notice Safety notice 1(Rev. 2008/08-a) Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situa- tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 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 Main- tenance 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. q Always wear safety glasses when hit- ting parts with a hammer. q 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 oper- ating 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 qualified workers must carry out work and operation which require license or qualification. 6) 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, fork- lift, service car, etc. 7) 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. 8) Before starting work, warm up your body thoroughly to start work under good condi- tion. 9) 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. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers 6 Safety check before starting work 7 Wearing protective goggles (for cleaning or grinding work) 8 Wearing shielding goggles and protectors (for welding work) 9 Good physical condition and preparation 10 Precautions against work which you are not used to or you are used to too much
SEN04932-01 D65EX, PX, WX-16 00-200 3 200 Foreword and general information Safety notice 2. Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, sup- port the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad- ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing compo- nents of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wir- ing. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electri- cal parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be dam- aged by contact with other parts when the machine is operated. 11) When installing high pressure hoses, make sure that they are not twisted. Dam- aged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate vio- lently or rotate at high speed, be particu- larly careful to check that they are installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are cor- rectly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accord- ingly, open the windows and doors to ven- tilate well.
SEN04932-01 00-200 4 D65EX, PX, WX-16 200 Foreword and general information Safety notice 4. Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original wind- ing position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes form- ing a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allow- able load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}. 8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper mate- rial to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle por- tion. 11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the follow- ing. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condi- tion of the slung load, wire ropes, and pads.
SEN05111-00 50-200 2 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel supply pump assembly Removal and installation of fuel supply pump assembly 1 Special tools Removal k Stop the machine on a level place and apply the parking brake. k Lower the work equipment to the ground and stop the engine. k Disconnect the cable from the negative (–) terminal of the battery. 1. Open fuel tank lower cover (1a). 2. Turn the fuel valve at the fuel tank bottom to the “CLOSE” position. 3. Open left engine side cover (1) and lock it. a Lock the cover securely. 4. Remove cover (2). 5. Remove 2 air conditioner hose clamps (3). 6. Remove air hose clamp (4) and disconnect air hose (5). [*1] 7. Remove 3 wiring harness clamps (6). 8. Disconnect wiring harness connectors CN-AC (7) and CN-ACG (8) and ground cable (9). 9. Remove air conditioner compressor (10). For details, see Testing and adjusting, “Testing and adjusting air conditioner compressor belt ten- sion”. [*2] a Fix air conditioner compressor (10) to the machine with a rope. 10. Disconnect wiring harness connector (11) from the fuel supply pump. 11. Remove hose clamp (12). 12. Disconnect overflow tube (13). [*3] Symbol Part No. Part name Necessity Q’ty New/Remodel Sketch A 1 795-799-1131 Gear t 1 2 795-799-1390 Remover t 1
SEN05111-00 D65EX, PX, WX-16 50-200 3 200 Engine and cooling system Removal and installation of fuel supply pump assembly 13. Remove the fuel scatter prevention caps at both ends and disconnect fuel high-pressure pipe (14). [*4] 14. Disconnect fuel hoses (15), (16) and (17) according to the following procedure. [*5] 1) While pushing part (a) of fuel hose (15) in the direction of the arrow, pull part (b) in the direction of the arrow to disconnect the fuel hose. 2) Disconnect fuel hoses (16) and (17) simi- larly. 15. To remove the air conditioner hose clamp, remove the following covers. 1) Remove cover (18). 2) Remove left step cover (19). a Remove the cover in order to remove air conditioner hose clamp. 16. Remove hose clamp (20). 17. Disconnect wiring harness connector CN- AC05 (21). 18. Remove receiver drier and bracket assembly (22). a Fix receiver drier and bracket assembly (22) to the machine.
SEN05111-00 50-200 4 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel supply pump assembly 19. Remove cap (23) from the flywheel housing and install engine cranking tool A1 (See the special tool table). a See Testing and adjusting, “Adjusting valve clearance”. 20. Loosen and remove cap (24). a Use a filter wrench etc. to remove cap (24). 21. Using tool A1, rotate the crankshaft forward (counterclockwise seeing from the flywheel side) and set stamp (M) of drive gear (GY) to the TDC (Top Dead Center). (See the special tool table) a Use a mirror to check the stamp etc. a See Testing and adjusting, “Adjusting valve clearance”. 22. Remove mounting nut (25) and washer (26) from fuel supply pump shaft (SH). a When removing mounting nut (25) and washer (26), take care not to drip them into the case. 23. Tighten tool A2 evenly to disconnect shaft (SH) of the fuel supply pump from drive gear (GY). 24. Remove bracket (27). 25. Remove 4 mounting nuts (28) and fuel supply pump assembly (29).
SEN05111-00 D65EX, PX, WX-16 50-200 5 200 Engine and cooling system Removal and installation of fuel supply pump assembly Installation q Install the fuel supply pump assembly accord- ing to the following procedure. 1. Install fuel supply pump assembly (29) while matching projection (P) of its shaft (SH) to groove (G) of gear (GY). 2. Install bracket (27) to fuel supply pump assem- bly (29). 3 Mounting bolt (27a): 65 ± 6 Nm {6.6 ± 0.6 kgm} 3 Mounting bolt (27b): 77 ± 12 Nm {7.9 ± 1.2 kgm} 3. Install 4 mounting nuts (28). 2 Mounting nut (28): Adhesive (LT-2) 3 Mounting nut (28): 43 ± 6 Nm {4.4 ± 0.6 kgm} 4. Install washer (26) and tighten mounting nut (25). a When installing mounting nut (25) and washer (26), take care not to drip them into the case. 3 Mounting nut (25): 180 ± 13 Nm {18.4 ± 1.3 kgm} q Carry out the following installation in the reverse order to removal. [*1] a Push in air hose (5) to the stopper of the tube securely. 3 Air hose mounting clamp (4): 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} [*2] a Install the air conditioner compressor. For detail, see Testing and adjusting, “Testing and adjusting air conditioner compressor belt ten- sion” and “Removal and installation of air con- ditioner compressor”. [*3] 3 Overflow tube (13) mounting joint bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
SEN05111-00 50-200 6 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel supply pump assembly [*4] q Install fuel high-pressure pipe (14) and install the fuel scatter prevention caps to both ends. a Tighten the sleeve nut of fuel high-pressure pipe (14) with the fingers at first, and then tighten them permanently. 3 Fuel high-pressure pipe (14) sleeve nut: 37.3 ± 4 Nm {3.8 ± 0.4 kgm} [*5] k Since the internal parts of the installed por- tions of fuel hoses (15), (16) and (17) may have been damaged, replace those hoses with new ones. q Checking for fuel leakage (Fuel system) Check the fuel system for leakage. For details, see Testing and adjusting, “Checking fuel sys- tem for leakage”. q Bleeding air (Fuel system) Bleed air from the fuel circuit. For details, see Testing and adjusting, “Bleeding air from fuel circuit”.
SEN05111-00 D65EX, PX, WX-16 50-200 7 200 Engine and cooling system Removal and installation of fuel injector assembly Removal and installation of fuel injector assembly 1 Special tools Removal k Stop the machine on a level place and apply the parking brake. k Lower the work equipment to the ground and stop the engine. k Disconnect the cable from the negative (–) terminal of the battery. 1. Open cover (1) under the fuel tank. 2. Turn the fuel valve at the fuel tank bottom to the “CLOSE” position. 3. Remove the engine hood assembly. For details, see “Removal and installation of engine hood assembly”. 4. Sling the muffler assembly temporarily. 5. Remove U-bolt (2) and mounting bolt (3). [*1] 6. Lift off muffler assembly (4). 4 Muffler assembly (4): 30 kg 7. Remove 3 air conditioner hose clamps (5). Symbol Part No. Part name Necessity Q’ty New/Remodel Sketch A 1 795-799-1131 Gear t 1 3 795-799-6700 Puller t 1 4 795-799-8150 Remover q 1
SEN05111-00 50-200 8 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel injector assembly 8. Remove wiring harness clamp (6). 9. Disconnect wiring harness connectors CN-AC (7) and CN-ACG (8) and ground cable (9). 10. Remove air conditioner compressor assembly (10). For details, see Testing and adjusting, “Testing and adjusting air conditioner compres- sor belt tension”. [*2] a Fix air conditioner compressor assembly (10) to the machine with a rope. 11. Remove tube clamp (11) and muffler water drain tube (12). 12. Remove bracket (13). 13. Remove wiring harness clamps (14), (15) and (16). 14. Disconnect the following wiring harness con- nectors. (17): CN-HTD (Disconnect from clamp) (18): CN-WIF (19): CN-HT/B (20): CN-HT/A (21): CN-HT/C (22): Ground 15. Remove plate (23). 16. Remove hose clamp (24) and disconnect air hose (25). [*3] 17. Disconnect wiring harness connectors CN-C8 (26) and CN-C17 (27). 18. Disconnect air tube (29). [*4]
SEN05111-00 D65EX, PX, WX-16 50-200 9 200 Engine and cooling system Removal and installation of fuel injector assembly 19. Remove left step cover (30). a Remove the left step cover to remove the air conditioner hose clamp. 20. Remove hose clamp (31). 21. Disconnect wiring harness connector CN- AC05 (32). 22. Remove receiver drier and bracket assembly (33). a Fix receiver drier and bracket assembly (33) to the machine. 23. Disconnect 2 heater hoses (34). 24. Disconnect 2 fuel hoses (35). [*5] a While pushing part (c) of fuel hose (35) in the direction of the arrow, pull part (d) in the direction of the arrow to disconnect the fuel hose. 25. Remove fuel filter and corrosion resistor assembly (36). 26. Disconnect wiring harness connector CN-C4 (37). a To disconnect wiring harness connector CN-C4 (37), slide lock (e) in the direction of the arrow and pull the connector toward you while pressing lock (f). a Even if lock (f) is pressed, the connector cannot be pulled out if part (g) does not float. In this case, float part (g) with a flat- head screwdriver while pressing lock (f) and pull out the connector toward you to disconnect.
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SEN05111-00 50-200 10 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel injector assembly 27. Remove bracket (38). 28. Remove wiring harness clamp (39). 29. Disconnect 3 fuel injector wiring harness con- nectors CN-C9 (41). 30. Remove bracket (42). 31. Remove the fuel scatter prevention caps at both ends and disconnect 6 fuel high-pressure pipes (43). [*6] 32. Remove hose clamp (44) and disconnect 2 blow-by hoses (45). 33. Remove cylinder head cover (46). [*7]
SEN05111-00 D65EX, PX, WX-16 50-200 11 200 Engine and cooling system Removal and installation of fuel injector assembly 34. Loosen 2 capture nuts (47) at the fuel injector head and disconnect fuel injector wiring har- ness (48). a Loosen the capture nuts alternately. a The capture nuts are not removable from the wiring harness. a Installed position of wiring harness 35. Loosen locknut (49) and loosen adjustment screw (50) by 2 – 3 turns. a Loosen the adjustment screw so that an excessive force will not be applied to the pushrod when the rocker arm is installed. 36. Remove mounting bolts (51) and rocker arm and crosshead assembly (52). a Record the installed position and direction (shapes of holes (a) and (b)) of the cross- head. (Install the crosshead in the recorded direction) 37. Remove retainer (53) and inlet connector (54). a Before removing retainer (53), remove all dirt and sand sticking to and around the retainer. a Tool A4 (remover) is set for removing inlet connector (54). (See the special tool table) 38. Remove 2 fuel injector holder mounting bolts (55). 39. Using tool A3, remove fuel injector holder (56) and fuel injector assembly (57) together. a Take care that dirt and foreign matter will not enter the mounting portion of fuel injector assembly (57). a Never hold the solenoid valve at the fuel injector top with pliers etc. Cable color Cylinder No. p Yellow May be installed reversely 1, 3, 5 q Orange r Red May be installed reversely 2, 4, 6 s Brown
SEN05111-00 50-200 12 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel injector assembly Installation q Fuel injector assembly a Check that the fuel injector installation hole is free from flaw and dirt. a When replacing the fuel injector assembly with new one, be sure to replace the inlet connec- tor, too. a Check the inlet connector visually for the fol- lowing defects. If it has any of those defects, replace it with new one. (a): There are burrs or deformation at the inlet or outlet of the inlet connector. (b): The edge filter is clogged or dirty. If there is sediment in it, it must not be reused. (c): The O-ring is cracked or deteriorated. (d): The outlet seal surface is worn or has a trace of bad contact or leakage. a If high-pressure fuel leaks, the seat surface is eroded and fine streaks or cracks are made. In this case, replace the inlet connector and fuel injector assembly with new ones. 1. Install gasket (58) and O-ring (59) to fuel injec- tor assembly (57). 2 O-ring (59) and fuel injector mounting hole: Engine oil (EO15W-40) 2. Install fuel injector holder (56) to fuel injector assembly (57). a Match the convex (A) and concave (B) parts. 3. Insert fuel injector assembly (57) in the cylin- der head with its fuel inlet hole directed toward the intake manifold. 4. Finger-tighten mounting bolts (55) of fuel injec- tor holder (56) 3 – 4 turns. 5. Install inlet connector (54) with retainer (53) temporarily. 2 O-ring of inlet connector (54) and mounting hole on cylinder head side: Engine oil (EO15W-40) 3 Retainer (53): 15 ± 5.0 Nm {1.5 ± 0.5 kgm} 6. Tighten mounting bolts (55) of fuel injector holder (56) alternately. 3 Fuel injector holder mounting bolt (55): 10 ± 2 Nm {1.0 ± 0.2 kgm} a The top of fuel injector holder (56) must be in parallel with the top of the cylinder head. Max. allowance: 2.4°

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Komatsu d65 wx 16 dozer bulldozer service repair manual sn 80001 and up

  • 1. BULLDOZER SEN04887-05 D65EX -16 D65PX -16 D65WX-16 SERIAL NUMBERS D65EX- 80001 D65PX- 80001 D65WX-80001 and up
  • 2. SEN04931-05 00-100 4 D65EX, PX, WX-16 Table of contents 100 Index Table of contents 1 00 Index and foreword 100 Index ..........................................................................................................................................SEN04931-05 Composition of shop manual......................................................................................................................... 2 Table of contents........................................................................................................................................... 4 200 Foreword and general information.............................................................................................SEN04932-01 Safety notice ................................................................................................................................................. 2 How to read the shop manual ....................................................................................................................... 7 Explanation of terms for maintenance standard............................................................................................ 9 Handling of electric equipment and hydraulic component............................................................................. 11 Handling of connectors newly used for engines............................................................................................ 20 How to read electric wire code...................................................................................................................... 23 Precautions when carrying out operation...................................................................................................... 26 Method of disassembling and connecting push-pull type coupler................................................................. 29 Standard tightening torque table ................................................................................................................... 32 Conversion table ........................................................................................................................................... 36 01 General 100 Specification and technical data.................................................................................................SEN04933-00 Specification dimension drawing................................................................................................................... 2 Specifications ................................................................................................................................................ 6 Weight table .................................................................................................................................................. 18 Table of fuel, coolant and lubricants.............................................................................................................. 22 10 Structure, function and maintenance standard 100 Engine and cooling system........................................................................................................SEN04963-00 Engine mount................................................................................................................................................ 3 Cooling system.............................................................................................................................................. 4 Cooling fan pump.......................................................................................................................................... 6 Cooling fan motor.......................................................................................................................................... 20 201 Power train, Part 1 .....................................................................................................................SEN04964-00 Power train.................................................................................................................................................... 2 HSS system .................................................................................................................................................. 4 Overall view of power train unit..................................................................................................................... 6 Power train hydraulic piping diagram............................................................................................................ 10 Transmission, steering and brake control ..................................................................................................... 12 Damper ......................................................................................................................................................... 14 Universal joint................................................................................................................................................ 16 Torque converter and PTO............................................................................................................................ 17 Transmission................................................................................................................................................. 24 Transmission control valve............................................................................................................................ 42 ECMV............................................................................................................................................................ 46 Main relief and torque converter relief valve ................................................................................................. 54 Transmission lubrication relief valve ............................................................................................................. 56 202 Power train, Part 2 .....................................................................................................................SEN04965-00 Bevel gear shaft, HSS and brake.................................................................................................................. 2 Brake valve ................................................................................................................................................... 24 Final drive...................................................................................................................................................... 30 300 Undercarriage and frame...........................................................................................................SEN04966-01 Main frame .................................................................................................................................................... 2 Suspension ................................................................................................................................................... 4 Track frame and idler cushion....................................................................................................................... 14 Idler ............................................................................................................................................................... 18 Track roller .................................................................................................................................................... 20 Carrier roller .................................................................................................................................................. 24 Sprocket ........................................................................................................................................................ 26
  • 3. SEN04931-05 D65EX, PX, WX-16 00-100 5 Table of contents 100 Index Track shoe..................................................................................................................................................... 30 401 Hydraulic system, Part 1 ........................................................................................................... SEN04967-00 Work equipment hydraulic system layout drawing ........................................................................................ 2 Work equipment control................................................................................................................................. 6 Hydraulic tank and filter ................................................................................................................................. 8 Scavenging pump.......................................................................................................................................... 10 Power train and steering lubrication pump .................................................................................................... 11 HSS pump ..................................................................................................................................................... 12 HSS motor..................................................................................................................................................... 31 402 Hydraulic system, Part 2 ........................................................................................................... SEN04968-01 Control valve.................................................................................................................................................. 2 CLSS ............................................................................................................................................................. 11 Function and operation of each valve............................................................................................................ 14 403 Hydraulic system, Part 3 ........................................................................................................... SEN04969-00 PPC valve (blade lift, blade tilt)...................................................................................................................... 2 PPC valve (ripper) ......................................................................................................................................... 8 Electric lever (steering).................................................................................................................................. 12 Quick drop valve............................................................................................................................................ 16 Work equipment lock solenoid valve ............................................................................................................. 18 Pitch selector solenoid valve ......................................................................................................................... 22 Hydraulic oil cooler bypass valve .................................................................................................................. 23 Accumulator................................................................................................................................................... 24 500 Work equipment ........................................................................................................................ SEN04970-00 Blade ............................................................................................................................................................. 2 Cutting edge and end bit ............................................................................................................................... 8 Ripper............................................................................................................................................................ 10 Hydraulic cylinder .......................................................................................................................................... 11 Piston valve ................................................................................................................................................... 14 600 Cab and its attachments............................................................................................................ SEN04971-00 Cab mount..................................................................................................................................................... 2 Cab................................................................................................................................................................ 3 700 Electrical system ....................................................................................................................... SEN04972-00 Monitor system .............................................................................................................................................. 2 Engine control system ................................................................................................................................... 18 Cooling system control system...................................................................................................................... 21 Electronic steering control system................................................................................................................. 23 KOMTRAX system ........................................................................................................................................ 26 System components...................................................................................................................................... 28 Sensor ........................................................................................................................................................... 36 20 Standard value table 100 Standard service value table ..................................................................................................... SEN05118-01 Standard service value table for engine ........................................................................................................ 2 Standard service value table for chassis ....................................................................................................... 4 30 Testing and adjusting 101 Testing and adjusting, Part 1..................................................................................................... SEN05119-02 Tools for testing, adjusting, and troubleshooting ........................................................................................... 2 Testing engine speed..................................................................................................................................... 5 Testing intake air pressure (boost pressure) ................................................................................................. 7 Testing exhaust temperature ......................................................................................................................... 9 Testing exhaust gas color.............................................................................................................................. 11 Adjusting valve clearance.............................................................................................................................. 12 Testing compression pressure....................................................................................................................... 14 Testing blow-by pressure............................................................................................................................... 18 Testing engine oil pressure............................................................................................................................ 19
  • 4. SEN04931-05 00-100 6 D65EX, PX, WX-16 Table of contents 100 Index Handling of fuel system devices.................................................................................................................... 20 Releasing residual pressure from fuel system .............................................................................................. 20 Testing fuel pressure..................................................................................................................................... 21 Testing fuel return and leak amount.............................................................................................................. 26 Bleeding air from fuel circuit.......................................................................................................................... 28 Testing fuel circuit for leakage....................................................................................................................... 29 Handling of reduced cylinder mode operation............................................................................................... 30 Handling of no injection cranking operation .................................................................................................. 30 Testing and adjusting air conditioner compressor belt tension...................................................................... 31 Replacing alternator belt ............................................................................................................................... 32 Adjusting fuel control dial and decelerator pedal .......................................................................................... 33 Handling controller high-voltage circuit ......................................................................................................... 34 102 Testing and adjusting, Part 2......................................................................................................SEN05120-01 Testing power train oil pressure .................................................................................................................... 3 Adjusting transmission output shaft speed sensor (replacement procedure) ............................................... 8 Simple test procedure for brake performance............................................................................................... 9 Adjusting brake pedal.................................................................................................................................... 10 Adjusting parking brake lever........................................................................................................................ 12 Emergency escape method when power train has trouble ........................................................................... 14 Adjusting clearance of idler........................................................................................................................... 17 Inspecting wear of sprocket .......................................................................................................................... 18 Testing and adjusting track shoe tension ...................................................................................................... 19 Testing and adjusting work equipment and HSS oil pressure....................................................................... 20 Testing control circuit basic pressure ............................................................................................................ 23 Testing PPC valve output pressure............................................................................................................... 24 Adjusting work equipment PPC valve play.................................................................................................... 26 Testing internal leakage of work equipment cylinder..................................................................................... 30 Bleeding air from work equipment cylinder ................................................................................................... 31 Releasing residual pressure from work equipment cylinder.......................................................................... 31 Checking parts which caused hydraulic drift of blade or ripper..................................................................... 32 Adjusting work equipment lock lever............................................................................................................. 33 Testing fan speed.......................................................................................................................................... 34 Testing fan circuit oil pressure....................................................................................................................... 35 Bleeding air from fan pump........................................................................................................................... 36 Bleeding air from HSS pump......................................................................................................................... 37 Adjusting straight tiltdozer............................................................................................................................. 38 Adjusting play of blade center ball ................................................................................................................ 40 Adjusting operator’s cab................................................................................................................................ 41 103 Testing and adjusting, Part 3......................................................................................................SEN05121-02 Special functions of machine monitor (EMMS) ............................................................................................. 2 104 Testing and adjusting, Part 4......................................................................................................SEN05122-01 Handling of voltage circuit of engine controller ............................................................................................. 2 Adjustment method when controller has been replaced ............................................................................... 3 Preparation work for troubleshooting of electrical system............................................................................. 5 Inspection procedure of diode....................................................................................................................... 9 Pm-Clinic service .......................................................................................................................................... 10 40 Troubleshooting 100 Failure code table and fuse locations ........................................................................................SEN05029-01 Failure codes table........................................................................................................................................ 2 Fuse locations............................................................................................................................................... 7 200 General information on troubleshooting.....................................................................................SEN05030-01 Points to remember when troubleshooting.................................................................................................... 2 How to proceed troubleshooting ................................................................................................................... 3 Checks before troubleshooting ..................................................................................................................... 4 Classification and procedures for troubleshooting ........................................................................................ 6 Symptom supposed to be failure and troubleshooting No. ........................................................................... 10
  • 5. SEN04931-05 D65EX, PX, WX-16 00-100 7 Table of contents 100 Index Information contained in troubleshooting table.............................................................................................. 12 Troubleshooting method for disconnecting wiring harness of pressure sensor system ................................ 14 Connector list and stereogram ...................................................................................................................... 16 Connection table for connector pin numbers................................................................................................. 30 T- branch box and T- branch adapter table ................................................................................................... 66 301 Troubleshooting by failure code (Display of code), Part 1......................................................... SEN05031-00 Failure code [1500L0] Transmission clutch: Abnormal.................................................................................. 3 Failure code [15SAL1] Forward clutch: Fill high............................................................................................ 4 Failure code [15SALH] Forward clutch: Fill low............................................................................................. 6 Failure code [15SBL1] Reverse clutch: Fill high............................................................................................ 8 Failure code [15SBLH] Reverse clutch: Fill low............................................................................................. 10 Failure code [15SEL1] Speed 1st clutch: Fill high ......................................................................................... 12 Failure code [15SELH] Speed 1st clutch: Fill low.......................................................................................... 14 Failure code [15SFL1] Speed 2nd clutch: Fill high ........................................................................................ 16 Failure code [15SFLH] Speed 2nd clutch: Fill low......................................................................................... 18 Failure code [15SGL1] Speed 3rd clutch: Fill high ........................................................................................ 20 Failure code [15SGLH] Speed 3rd clutch: Fill low ......................................................................................... 22 Failure code [15SJL1] L/U: Fill high............................................................................................................... 24 Failure code [15SJLH] L/U: Fill low ............................................................................................................... 26 Failure code [AB00MA] Battery Charge Abnormal........................................................................................ 28 Failure code [B@BAZG] Eng Oil Press Low ................................................................................................. 30 Failure code [B@BCNS] Eng Water Overheat .............................................................................................. 30 Failure code [B@CENS] T/C Oil Overheat.................................................................................................... 31 Failure code [B@HANS] Hyd Oil Overheat ................................................................................................... 31 302 Troubleshooting by failure code (Display of code), Part 2......................................................... SEN05032-01 Failure code [CA111] ECM Critical Internal Failure ....................................................................................... 3 Failure code [CA115] Eng Ne and Bkup Speed Sens Error .......................................................................... 3 Failure code [CA122] Chg Air Press Sensor High Error................................................................................ 4 Failure code [CA123] Chg Air Press Sensor Low Error................................................................................. 6 Failure code [CA131] Throttle Sensor High Error.......................................................................................... 8 Failure code [CA132] Throttle Sensor Low Error........................................................................................... 10 Failure code [CA144] Coolant Temp Sens High Error................................................................................... 12 Failure code [CA145] Coolant Temp Sens Low Error.................................................................................... 14 Failure code [CA153] Chg Air Temp Sensor High Error ................................................................................ 16 Failure code [CA154] Chg Air Temp Sensor Low Error................................................................................. 18 Failure code [CA155] Chg Air Temp High Speed Derate............................................................................... 20 Failure code [CA187] Sens Supply 2 Volt Low Error..................................................................................... 22 Failure code [CA221] Ambient Press Sens High Error.................................................................................. 24 Failure code [CA222] Ambient Press Sens Low Error................................................................................... 26 Failure code [CA227] Sens Supply 2 Volt High Error .................................................................................... 28 Failure code [CA234] Eng Overspeed........................................................................................................... 28 Failure code [CA238] Ne Speed Sens Supply Volt Error............................................................................... 29 Failure code [CA271] IMV/PCV1 Short Error ................................................................................................ 30 Failure code [CA272] IMV/PCV1 Open Error ................................................................................................ 32 Failure code [CA281] Abnormal supply pump pressure balance .................................................................. 34 Failure code [CA322] Inj #1(L#1) Open/Short Error ...................................................................................... 36 Failure code [CA323] Inj #5(L#5) Open/Short Error ...................................................................................... 38 Failure code [CA324] Inj #3(L#3) Open/Short Error ...................................................................................... 40 Failure code [CA325] Inj #6(L#6) Open/Short Error ...................................................................................... 42 Failure code [CA331] Inj #2(L#2) Open/Short Error ...................................................................................... 44 Failure code [CA332] Inj #4(L#4) Open/Short Error ...................................................................................... 46 303 Troubleshooting by failure code (Display of code), Part 3......................................................... SEN05033-01 Failure code [CA342] Calibration Code Incompatibility ................................................................................. 3 Failure code [CA351] Injectors Drive Circuit Error......................................................................................... 3 Failure code [CA352] Sens Supply 1 Volt Low Error..................................................................................... 4 Failure code [CA386] Sens Supply 1 Volt High Error .................................................................................... 6 Failure code [CA428] Water in Fuel Sensor High Error................................................................................. 8 Failure code [CA429] Water in Fuel Sensor Low Error.................................................................................. 10
  • 6. SEN04931-05 00-100 8 D65EX, PX, WX-16 Table of contents 100 Index Failure code [CA435] Eng Oil Press Sw Error .............................................................................................. 12 Failure code [CA441] Battery Voltage Low Error .......................................................................................... 14 Failure code [CA442] Battery Voltage High Error.......................................................................................... 16 Failure code [CA449] Rail Press Very High Error ......................................................................................... 18 Failure code [CA451] Rail Press Sensor High Error ..................................................................................... 20 Failure code [CA452] Rail Press Sensor Low Error...................................................................................... 22 Failure code [CA488] Chg Air Temp High Torque Derate ............................................................................. 24 Failure code [CA553] Rail Press High Error.................................................................................................. 25 Failure code [CA559] Rail Press Low Error .................................................................................................. 26 Failure code [CA689] Eng Ne Speed Sensor Error....................................................................................... 28 Failure code [CA731] Eng Bkup Speed Sens Phase Error ........................................................................... 32 Failure code [CA757] All Continuous Data Lost Error................................................................................... 33 Failure code [CA778] Eng Bkup Speed Sensor Error ................................................................................... 34 Failure code [CA1633] KOMNET Datalink Timeout Error ............................................................................. 37 Failure code [CA2185] Throt Sens Sup Volt High Error................................................................................ 38 Failure code [CA2186] Throt Sens Sup Volt Low Error................................................................................. 40 Failure code [CA2249] Rail Press Very Low Error ........................................................................................ 42 Failure code [CA2265] Fuel Feed Pump Open Error.................................................................................... 44 Failure code [CA2266] Fuel Feed Pump Short Error .................................................................................... 46 Failure code [CA2311] IMV Solenoid Error ................................................................................................... 47 Failure code [CA2555] Grid Htr Relay Volt High Error .................................................................................. 48 Failure code [CA2556] Grid Htr Relay Volt Low Error................................................................................... 50 304 Troubleshooting by failure code (Display of code), Part 4 .........................................................SEN05034-01 Failure code [D110KB] Battery relay drive: Short circuit ............................................................................... 4 Failure code [D130KA] Neutral relay: Disconnection.................................................................................... 6 Failure code [D130KB] Neutral relay: Short circuit........................................................................................ 8 Failure code [D161KA] Back-up alarm relay: Disconnection ........................................................................ 10 Failure code [D161KB] Back-up alarm relay: Short circuit............................................................................ 12 Failure code [D862KA] GPS Antenna Open Circuit...................................................................................... 14 Failure code [DAFRKR] CAN Disconnection ................................................................................................ 15 Failure code [DAFRMC] CAN Discon (Monitor Detected)............................................................................. 16 Failure code [DB2RKR] CAN Disconnection................................................................................................. 19 Failure code [DBE0KT] PT controller: Abnormality in controller ................................................................... 24 Failure code [DBE1KK] Battery direct Source voltage reduction .................................................................. 26 Failure code [DBE2KK] Solenoid Source voltage reduction ......................................................................... 28 Failure code [DBE5KK] PT cont.: Sensor voltage 5V (1) reduction .............................................................. 30 Failure code [DBE6KK] PT cont.: Sensor voltage 24V reduction.................................................................. 32 Failure code [DBE7KK] PT cont.: Sensor voltage 5V (2) reduction .............................................................. 34 Failure code [DBE9KQ] PT controller: Type select signal............................................................................. 36 Failure code [DD12KA] Shift up Sw: Disconnection...................................................................................... 38 Failure code [DD12KB] Shift up Sw: Short circuit ......................................................................................... 40 Failure code [DD13KA] Shift down Sw: Disconnection................................................................................. 42 Failure code [DD13KB] Shift down Sw: Short circuit..................................................................................... 44 Failure code [DD14KA] Parking lever Sw: Disconnection............................................................................. 46 Failure code [DD14KB] Parking lever Sw: Short circuit ................................................................................ 48 305 Troubleshooting by failure code (Display of code), Part 5 .........................................................SEN05035-00 Failure code [DDN7KA] WEQ Knob Sw (down): Disconnection ................................................................... 4 Failure code [DDN7KB] WEQ Knob Sw (down): Short circuit....................................................................... 6 Failure code [DDN8KA] WEQ Knob Sw (up): Disconnection........................................................................ 8 Failure code [DDN8KB] WEQ Knob Sw (up): Short circuit ........................................................................... 10 Failure code [DDNLKA] Weq lock Sw: Disconnection .................................................................................. 12 Failure code [DDNLKB] Weq lock Sw: Short circuit ...................................................................................... 14 Failure code [DGS1KX] Hyd oil temp sensor: Abnormal............................................................................... 16 Failure code [DGT1KA] T/C oil temp sensor: Disconnection ........................................................................ 18 Failure code [DGT1KX] T/C oil temp sensor: Short circuit ............................................................................ 20 Failure code [DH21KA] Weq pressure sensor: Disconnection...................................................................... 22 Failure code [DH21KB] Weq pressure sensor: Short circuit ......................................................................... 24 Failure code [DHT5KA] T/C pressure sensor: Disconnection....................................................................... 26
  • 7. SEN04931-05 D65EX, PX, WX-16 00-100 9 Table of contents 100 Index Failure code [DHT5KB] T/C pressure sensor: Short circuit........................................................................... 28 Failure code [DK10KA] Fuel control Dial: Disconnection .............................................................................. 30 Failure code [DK10KB] Fuel control Dial: Short circuit.................................................................................. 32 Failure code [DK30KA] ST lever 1: Disconnection........................................................................................ 34 Failure code [DK30KB] ST lever 1: Short circuit............................................................................................ 36 Failure code [DK30KX] ST lever: Out of normal range.................................................................................. 38 Failure code [DK30KZ] ST lever: Disconnection or short circuit.................................................................... 38 Failure code [DK30L8] ST lever: Signal mismatch........................................................................................ 39 Failure code [DK31KA] ST lever 2: Disconnection........................................................................................ 40 Failure code [DK31KB] ST lever 2: Short circuit............................................................................................ 42 Failure code [DK40KA] Brake potentiometer: Disconnection........................................................................ 44 Failure code [DK40KB] Brake potentiometer: Short circuit............................................................................ 46 Failure code [DK55KX] FR lever: Out of normal range ................................................................................. 48 Failure code [DK55KZ] FR lever: Disconnection or short circuit ................................................................... 48 Failure code [DK55L8] FR lever: Signal mismatch........................................................................................ 49 Failure code [DK56KA] FR lever 1: Disconnection........................................................................................ 50 Failure code [DK56KB] FR lever 1: Short circuit ........................................................................................... 52 Failure code [DK57KA] FR lever 2: Disconnection........................................................................................ 54 Failure code [DK57KB] FR lever 2: Short circuit ........................................................................................... 56 306 Troubleshooting by failure code (Display of code), Part 6......................................................... SEN05036-01 Failure code [DKH1KA] Pitch angle sensor: Disconnection .......................................................................... 4 Failure code [DKH1KB] Pitch angle sensor: Short circuit.............................................................................. 6 Failure code [DLT3KA] T/M out-speed sensor: Disconnection...................................................................... 8 Failure code [DLT3KB] T/M out-speed sensor: Abnormal ............................................................................. 9 Failure code [DW5AKA] Pitch selector Sol.: Disconnection .......................................................................... 10 Failure code [DW5AKB] Pitch selector Sol.: Short circuit.............................................................................. 11 Failure code [DW5AKY] Pitch selector Sol.: Short circuit.............................................................................. 12 Failure code [DW7BKA] Fan rev EPC: Disconnection .................................................................................. 14 Failure code [DW7BKB] Fan rev EPC: Short circuit...................................................................................... 15 Failure code [DWN1KA] Hss EPC1: Disconnection ...................................................................................... 16 Failure code [DWN1KB] Hss EPC1: Short circuit.......................................................................................... 17 Failure code [DWN1KY] Hss EPC1: Short circuit.......................................................................................... 18 Failure code [DWN2KA] Hss EPC2: Disconnection ...................................................................................... 19 Failure code [DWN2KB] Hss EPC2: Short circuit.......................................................................................... 20 Failure code [DWN2KY] Hss EPC2: Short circuit.......................................................................................... 21 Failure code [DWN5KA] Fan pump solenoid: Disconnection ........................................................................ 22 Failure code [DWN5KB] Fan pump solenoid: Short circuit............................................................................ 23 Failure code [DWN5KY] Fan control solenoid: Short circuit.......................................................................... 24 Failure code [DXA0KA] TVC Sol.: Disconnection.......................................................................................... 26 Failure code [DXA0KB] TVC Sol.: Short circuit ............................................................................................. 27 Failure code [DXA0KY] TVC Sol.: Short circuit ............................................................................................. 28 Failure code [DXH1KA] Lock-up ECMV: Disconnection................................................................................ 29 Failure code [DXH1KB] Lock-up ECMV: Short circuit ................................................................................... 30 Failure code [DXH1KY] Lock-up ECMV: Short circuit ................................................................................... 32 Failure code [DXH4KA] 1st clutch ECMV: Disconnection ............................................................................. 34 Failure code [DXH4KB] 1st clutch ECMV: Short circuit................................................................................. 35 Failure code [DXH4KY] 1st clutch ECMV: Short circuit................................................................................. 36 Failure code [DXH5KA] 2nd clutch ECMV: Disconnection ............................................................................ 37 Failure code [DXH5KB] 2nd clutch ECMV: Short circuit................................................................................ 38 Failure code [DXH5KY] 2nd clutch ECMV: Short circuit................................................................................ 39 Failure code [DXH6KA] 3rd clutch ECMV: Disconnection............................................................................. 40 Failure code [DXH6KB] 3rd clutch ECMV: Short circuit................................................................................. 41 Failure code [DXH6KY] 3rd clutch ECMV: Short circuit................................................................................. 42 Failure code [DXH7KA] R clutch ECMV: Disconnection................................................................................ 43 Failure code [DXH7KB] R clutch ECMV: Short circuit ................................................................................... 44 Failure code [DXH7KY] R clutch ECMV: Short circuit ................................................................................... 46 Failure code [DXH8KA] F clutch ECMV: Disconnection................................................................................ 48 Failure code [DXH8KB] F clutch ECMV: Short circuit.................................................................................... 49
  • 8. SEN04931-05 00-100 10 D65EX, PX, WX-16 Table of contents 100 Index Failure code [DXH8KY] F clutch ECMV: Short circuit ................................................................................... 50 Failure code [DXJ4KA] Weq lock Sol.: Disconnection .................................................................................. 52 Failure code [DXJ4KB] Weq lock Sol.: Short circuit...................................................................................... 53 400 Troubleshooting of electrical system (E-mode)..........................................................................SEN05037-01 Before troubleshooting of electrical system .................................................................................................. 3 Information in troubleshooting table.............................................................................................................. 5 E-1 Engine does not start (starting motor does not turn) .............................................................................. 7 E-2 Preheater does not operate.................................................................................................................... 10 E-3 When starting switch is turned ON, machine monitor displays nothing.................................................. 16 E-4 When starting switch is turned ON (before starting engine), basic check item lights up ........................ 18 E-5 Precaution item lights up while engine is running................................................................................... 20 E-6 Emergency stop item lights up while engine is running.......................................................................... 22 E-7 Engine coolant temperature gauge does not indicate normally.............................................................. 24 E-8 Fuel gauge does not indicate properly ................................................................................................... 26 E-9 Power train oil temperature gauge (multi-gauge) does not indicate normally ........................................ 29 E-10 Hydraulic temperature gauge (multi-gauge) does not indicate normally .............................................. 30 E-11 Contents of display by machine monitor are different from applicable machine................................... 31 E-12 Machine monitor does not display some items..................................................................................... 31 E-13 Function switch does not work ............................................................................................................. 31 E-14 Operation mode does not change ........................................................................................................ 32 E-15 Gearshift mode does not change ......................................................................................................... 32 E-16 Customize function does not operate normally .................................................................................... 33 E-17 Customize memory function does not operate normally ...................................................................... 33 E-18 Alarm buzzer does not sound or does not stop.................................................................................... 34 E-19 When starting switch is turned OFF, service meter is not displayed .................................................... 34 E-20 Machine monitor cannot be set in service mode .................................................................................. 34 E-21 Horn does not sound or does not stop ................................................................................................. 35 E-22 Back-up alarm does not sound or does not stop.................................................................................. 36 E-23 Head lamp or rear lamp does not light up ............................................................................................ 38 E-24 Windshield wiper does not operate ...................................................................................................... 42 E-25 Window washer does not operate ........................................................................................................ 56 E-26 KOMTRAX system does not operate correctly..................................................................................... 61 500 Troubleshooting of hydraulic and mechanical system (H-mode) ...............................................SEN05038-00 Failure mode and cause table....................................................................................................................... 2 Contents of troubleshooting table ................................................................................................................. 4 H-1 There is no travel power (no drawbar pull)............................................................................................. 5 H-2 Machine does not move (at 2nd or 3rd speed)....................................................................................... 6 H-3 Machine does not move at any gear speed ........................................................................................... 7 H-4 Machine travels only in one direction, forward or in reverse .................................................................. 8 H-5 When gear is shifted or travel direction is changed, large time lag is made .......................................... 9 H-6 Machine cannot be steered (Machine does not turn leftward or rightward) ........................................... 10 H-7 Steering speed or power is low .............................................................................................................. 10 H- 8 Brake does not work.............................................................................................................................. 11 H-9 Overheat of power train oil ..................................................................................................................... 12 H-10 Abnormal sound comes out from around HSS and work equipment pump or HSS motor................... 13 H-11 All work equipment speeds are slow .................................................................................................... 13 H-12 Work equipment does not move........................................................................................................... 14 H-13 Blade lift speed is slow or lacks power................................................................................................. 14 H-14 Blade tilt speed is slow or lacks power................................................................................................. 15 H-15 Ripper lift speed is slow or lacks power ............................................................................................... 15 H-16 Excessive hydraulic drift of blade lift..................................................................................................... 16 H-17 Excessive hydraulic drift of blade tilt .................................................................................................... 16 H-18 Excessive hydraulic drift of ripper lift .................................................................................................... 17 600 Troubleshooting of engine (S-mode)..........................................................................................SEN05039-00 Method of using troubleshooting charts ........................................................................................................ 3 S-1 Starting performance is poor................................................................................................................... 6 S-2 Engine does not start.............................................................................................................................. 7 S-3 Engine does not pick up smoothly.......................................................................................................... 10
  • 9. SEN04931-05 D65EX, PX, WX-16 00-100 11 Table of contents 100 Index S-4 Engine stops during operations .............................................................................................................. 11 S-5 Engine does not rotate smoothly ............................................................................................................ 12 S-6 Engine lacks output (or lacks power)...................................................................................................... 13 S-7 Exhaust smoke is black (incomplete combustion) .................................................................................. 14 S-8 Oil consumption is excessive (or exhaust smoke is blue)....................................................................... 15 S-9 Oil becomes contaminated quickly ......................................................................................................... 16 S-10 Fuel consumption is excessive ............................................................................................................. 17 S-11 Oil is in coolant (or coolant spurts back, or coolant level goes down)................................................... 18 S-12 Oil pressure drops................................................................................................................................. 19 S-13 Oil level rises (water, fuel in oil) ............................................................................................................ 20 S-14 Coolant temperature becomes too high (overheating).......................................................................... 21 S-15 Abnormal noise is made ....................................................................................................................... 22 S-16 Vibration is excessive ........................................................................................................................... 23 50 Disassembly and assembly 100 General information on disassembly and assembly.................................................................. SEN05110-00 How to read this manual................................................................................................................................ 2 Coating materials list ..................................................................................................................................... 4 Special tool list............................................................................................................................................... 7 Sketches of special tools............................................................................................................................... 16 200 Engine and cooling system ........................................................................................................SEN05111-00 Removal and installation of fuel supply pump assembly............................................................................... 2 Removal and installation of fuel injector assembly........................................................................................ 7 Removal and installation of cylinder head assembly..................................................................................... 17 Removal and installation of radiator assembly.............................................................................................. 32 Removal and installation of aftercooler assembly ......................................................................................... 35 Removal and installation of hydraulic oil cooler assembly ............................................................................ 37 Removal and installation of power train oil cooler assembly......................................................................... 39 Removal and installation of cooling fan drive assembly................................................................................ 42 Removal and installation of cooling fan motor assembly............................................................................... 44 Removal and installation of engine assembly ............................................................................................... 46 Removal and installation of damper assembly.............................................................................................. 54 Removal and installation of engine front oil seal ........................................................................................... 57 Removal and installation of engine rear oil seal............................................................................................ 61 Removal and installation of engine hood assembly ...................................................................................... 69 Removal and installation of fuel tank assembly............................................................................................. 71 300 Power train ................................................................................................................................ SEN05112-00 Removal and installation of power train unit assembly.................................................................................. 2 Separation and connection of power train unit assembly.............................................................................. 6 Disassembly and assembly of PTO assembly............................................................................................... 11 Disassembly and assembly of torque converter assembly............................................................................ 16 Disassembly and assembly of transmission assembly.................................................................................. 27 Disassembly and assembly of HSS assembly .............................................................................................. 54 Removal and installation of final drive assembly........................................................................................... 74 Disassembly and assembly of final drive assembly ...................................................................................... 76 400 Undercarriage and frame .......................................................................................................... SEN05113-01 Removal and installation of track frame assembly ........................................................................................ 2 Removal and installation of idler assembly ................................................................................................... 4 Disassembly and assembly of idler assembly............................................................................................... 6 Removal and installation of recoil spring assembly....................................................................................... 10 Disassembly and assembly of recoil spring assembly .................................................................................. 11 Removal and installation of track roller assembly ......................................................................................... 15 Disassembly and assembly of track roller assembly..................................................................................... 16 Removal and installation of carrier roller assembly ....................................................................................... 20 Disassembly and assembly of carrier roller assembly................................................................................... 21 Expansion and installation of track shoe assembly (Conventional type track shoe) ..................................... 24 Expansion and installation of track shoe assembly (PLUS type track shoe)................................................. 27
  • 10. SEN04931-05 00-100 12 D65EX, PX, WX-16 Table of contents 100 Index Whole disassembly and whole assembly of track shoe assembly (Conventional type track shoe).............. 28 Whole disassembly and whole assembly of track shoe assembly (PLUS type track shoe).......................... 42 Field disassembly and assembly of one link (Conventional type track shoe) ............................................... 54 Field disassembly and assembly of one link (PLUS type track shoe)........................................................... 61 Removal and installation of pivot shaft assembly.......................................................................................... 66 Removal and installation of equalizer bar assembly..................................................................................... 67 Disassembly and assembly of equalizer bar side bushing............................................................................ 69 500 Hydraulic system........................................................................................................................SEN05114-00 Removal and installation of hydraulic tank assembly.................................................................................... 2 Removal and installation of control valve assembly...................................................................................... 5 Disassembly and assembly of control valve assembly ................................................................................. 8 Disassembly and assembly of blade lift and tilt PPC valve assembly........................................................... 10 Disassembly and assembly of ripper PPC valve assembly .......................................................................... 11 Removal and installation of HSS and cooling fan pump assembly............................................................... 12 Removal and installation of power train and lubrication pump assembly...................................................... 14 Removal and installation of scavenging pump assembly.............................................................................. 16 Removal and installation of HSS motor assembly ........................................................................................ 17 Disassembly and assembly of hydraulic cylinder assembly.......................................................................... 20 600 Work equipment.........................................................................................................................SEN05115-00 Removal and installation of blade assembly (ST-TPP dozer) ....................................................................... 2 Removal and installation of blade assembly (PAT dozer) ............................................................................. 5 Removal and installation of ripper assembly................................................................................................. 7 700 Cab and its attachments ............................................................................................................SEN05116-00 Removal and installation of ROPS cab assembly......................................................................................... 2 Removal and installation of operator’s cab glass (Stuck glass) .................................................................... 9 Removal and installation of air conditioner unit assembly ............................................................................ 15 Removal and installation of air conditioner compressor assembly ............................................................... 19 800 Electrical system........................................................................................................................SEN05117-00 Removal and installation of monitor panel assembly .................................................................................... 2 Removal and installation of engine controller assembly ............................................................................... 4 Removal and installation of power train controller assembly ........................................................................ 6 Removal and installation of KOMTRAX terminal assembly .......................................................................... 8 80 Appendix 100 Air conditioner............................................................................................................................SEN05041-00 Structure and function....................................................................................................................................... 4 Air conditioner component ............................................................................................................................ 4 Configuration and function of refrigerating cycle........................................................................................... 6 Outline of refrigerating cycle ......................................................................................................................... 7 Air conditioner unit ........................................................................................................................................ 10 Control plate.................................................................................................................................................. 14 Compressor................................................................................................................................................... 15 Condenser..................................................................................................................................................... 16 Receiver drier................................................................................................................................................ 17 Testing, adjusting and troubleshooting ............................................................................................................. 18 Caution about refrigerant .............................................................................................................................. 18 Troubleshooting procedure ........................................................................................................................... 19 Block diagram ............................................................................................................................................... 20 Circuit diagram and arrangement of connector pins ..................................................................................... 22 Detail of air conditioner unit........................................................................................................................... 24 Parts and connectors arrangement............................................................................................................... 26 Testing air leakage (duct).............................................................................................................................. 32 Testing with self-diagnosis function............................................................................................................... 34 Testing temperature control........................................................................................................................... 37 Testing vent (mode) changeover................................................................................................................... 39 Testing Recirc/Fresh changeover.................................................................................................................. 42 Testing inner sensor...................................................................................................................................... 43
  • 11. SEN04931-05 D65EX, PX, WX-16 00-100 13 Table of contents 100 Index Testing evaporator temperature sensor......................................................................................................... 44 Testing sunlight sensor.................................................................................................................................. 47 Testing (dual) pressure switch for refrigerant ................................................................................................ 48 Testing relays and diodes.............................................................................................................................. 50 Troubleshooting chart 1................................................................................................................................. 52 Troubleshooting chart 2................................................................................................................................. 53 Troubleshooting for electrical system (E mode) ............................................................................................ 56 E-1 Power supply system (Air conditioner does not operate)..................................................................... 57 E-2 Compressor and refrigerant system (Air is not cooled)........................................................................ 60 E-3 Blower motor system (No air comes out or air flow is abnormal)......................................................... 63 E-4 Temperature cannot be controlled ....................................................................................................... 66 E-5 Vent (mode) cannot be changed over.................................................................................................. 68 E-6 Recirc/Fresh air cannot be changed over............................................................................................ 70 Troubleshooting with gauge pressure............................................................................................................ 72 Connection of service tool ............................................................................................................................. 75 Precautions for connecting air conditioner piping.......................................................................................... 76 Handling of compressor oil............................................................................................................................ 77 1. Control of compressor oil (Denso: ND-OIL8: For R134a)..................................................................... 77 2. Adding of compressor oil ...................................................................................................................... 77 3. Compressor replacement ..................................................................................................................... 78 4. Applying compressor oil for O-ring ....................................................................................................... 78 90 Diagrams and drawings 100 Hydraulic diagrams and drawings ............................................................................................. SEN04934-00 Power train hydraulic circuit diagram............................................................................................................. 3 Work equipment hydraulic circuit diagram..................................................................................................... 5 200 Electrical diagrams and drawings.............................................................................................. SEN04935-00 Electrical circuit diagram................................................................................................................................ 3
  • 12. SEN04932-01 00-200 2 D65EX, PX, WX-16 200 Foreword and general information Safety notice Safety notice 1(Rev. 2008/08-a) Important safety notice Proper service and repair are extremely important for safe machine operation. The service and repair techniques recommended by Komatsu and described in this manual are both effective and safe. Some of these techniques require the use of tools specially designed by Komatsu for the specific purpose. To prevent injury to workers, the symbol k is used to mark safety precautions in this manual. The cautions accompanying these symbols should always be followed carefully. If any dangerous situa- tion arises or may possibly arise, first consider safety, and take the necessary actions to deal with the situation. 1. General precautions k Mistakes in operation are extremely dangerous. Read the Operation and Maintenance Manual carefully before operating the machine. In addition, read this manual and understand its contents before starting the work. 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 Main- tenance 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. q Always wear safety glasses when hit- ting parts with a hammer. q 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 oper- ating 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 qualified workers must carry out work and operation which require license or qualification. 6) 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, fork- lift, service car, etc. 7) 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. 8) Before starting work, warm up your body thoroughly to start work under good condi- tion. 9) 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. Safety points 1 Good arrangement 2 Correct work clothes 3 Following work standard 4 Making and checking signs 5 Prohibition of operation and handling by unlicensed workers 6 Safety check before starting work 7 Wearing protective goggles (for cleaning or grinding work) 8 Wearing shielding goggles and protectors (for welding work) 9 Good physical condition and preparation 10 Precautions against work which you are not used to or you are used to too much
  • 13. SEN04932-01 D65EX, PX, WX-16 00-200 3 200 Foreword and general information Safety notice 2. Preparations for work 1) Before adding oil or making any repairs, park the machine on a hard and level ground, and apply the parking brake and block the wheels or tracks to prevent the machine from moving. 2) Before starting work, lower the work equipment (blade, ripper, bucket, etc.) to the ground. If this is not possible, insert the lock pin or use blocks to prevent the work equipment from falling. In addition, be sure to lock all the control levers and hang warning signs on them. 3) When disassembling or assembling, sup- port the machine with blocks, jacks, or stands before starting work. 4) Remove all mud and oil from the steps or other places used to get on and off the machine. Always use the handrails, lad- ders or steps when getting on or off the machine. Never jump on or off the machine. If it is impossible to use the handrails, ladders or steps, use a stand to provide safe footing. 3. Precautions during work 1) Before disconnecting or removing compo- nents of the oil, water, or air circuits, first release the pressure completely from the circuit. When removing the oil filler cap, a drain plug, or an oil pressure pickup plug, loosen it slowly to prevent the oil from spurting out. 2) The coolant and oil in the circuits are hot when the engine is stopped, so be careful not to get scalded. Wait for the oil and coolant to cool before carrying out any work on the oil or water circuits. 3) Before starting work, stop the engine. When working on or around a rotating part, in particular, stop the engine. When checking the machine without stopping the engine (measuring oil pressure, revolving speed, temperature, etc.), take extreme care not to get rolled or caught in rotating parts or moving parts. 4) Before starting work, remove the leads from the battery. Always remove the lead from the negative (–) terminal first. 5) When raising a heavy component (heavier than 25 kg), use a hoist or crane. Before starting work, check that the slings (wire ropes, chains, and hooks) are free from damage. Always use slings which have ample capacity and install them to proper places. Operate the hoist or crane slowly to prevent the component from hitting any other part. Do not work with any part still raised by the hoist or crane. 6) When removing a cover which is under internal pressure or under pressure from a spring, always leave 2 bolts in diagonal positions. Loosen those bolts gradually and alternately to release the pressure, and then remove the cover. 7) When removing components, be careful not to break or damage the electrical wir- ing. Damaged wiring may cause electrical fires. 8) When removing piping, stop the fuel or oil from spilling out. If any fuel or oil drips onto the floor, wipe it up immediately. Fuel or oil on the floor can cause you to slip and can even start fires. 9) As a general rule, do not use gasoline to wash parts. Do not use it to clean electri- cal parts, in particular. 10) Be sure to assemble all parts again in their original places. Replace any damaged parts and parts which must not be reused with new parts. When installing hoses and wires, be sure that they will not be dam- aged by contact with other parts when the machine is operated. 11) When installing high pressure hoses, make sure that they are not twisted. Dam- aged tubes are dangerous, so be extremely careful when installing tubes for high pressure circuits. In addition, check that connecting parts are correctly installed. 12) When assembling or installing parts, always tighten them to the specified torques. When installing protective parts such as guards, or parts which vibrate vio- lently or rotate at high speed, be particu- larly careful to check that they are installed correctly. 13) When aligning 2 holes, never insert your fingers or hand. Be careful not to get your fingers caught in a hole. 14) When measuring hydraulic pressure, check that the measuring tools are cor- rectly assembled. 15) Take care when removing or installing the tracks of track-type machines. When removing the track, the track separates suddenly, so never let anyone stand at either end of the track. 16) If the engine is operated for a long time in a place which is not ventilated well, you may suffer from gas poisoning. Accord- ingly, open the windows and doors to ven- tilate well.
  • 14. SEN04932-01 00-200 4 D65EX, PX, WX-16 200 Foreword and general information Safety notice 4. Precautions for sling work and making signs 1) Only one appointed worker must make signs and co-workers must communicate with each other frequently. The appointed sign maker must make specified signs clearly at a place where he is well seen from the operator's seat and where he can see the working condition easily. The sign maker must always stand in front of the load and guide the operator safely. q Do not stand under the load. q Do not step on the load. 2) Check the slings before starting sling work. 3) Keep putting on gloves during sling work. (Put on leather gloves, if available.) 4) Measure the weight of the load by the eye and check its center of gravity. 5) Use proper sling according to the weight of the load and method of slinging. If too thick wire ropes are used to sling a light load, the load may slip and fall. 6) Do not sling a load with 1 wire rope alone. If it is slung so, it may rotate and may slip out of the rope. Install 2 or more wire ropes symmetrically. k Slinging with 1 rope may cause turning of the load during hoisting, untwisting of the rope, or slipping of the rope from its original wind- ing position on the load, which can result in a dangerous accident. 7) Limit the hanging angle to 60°, as a rule. Do not sling a heavy load with ropes form- ing a wide hanging angle from the hook. When hoisting a load with 2 or more ropes, the force subjected to each rope will increase with the hanging angle. The table below shows the variation of allow- able load in kN {kg} when hoisting is made with 2 ropes, each of which is allowed to sling up to 9.8 kN {1,000 kg} vertically, at various hanging angles. When the 2 ropes sling a load vertically, up to 19.6 kN {2,000 kg} of total weight can be suspended. This weight is reduced to 9.8 kN {1,000 kg} when the 2 ropes make a hanging angle of 120°. If the 2 ropes sling a 19.6 kN {2,000 kg} load at a lifting angle of 150°, each of them is subjected to a force as large as 39.2 kN {4,000 kg}. 8) When installing wire ropes to an angular load, apply pads to protect the wire ropes. If the load is slippery, apply proper mate- rial to prevent the wire rope from slipping. 9) Use the specified eyebolts and fix wire ropes, chains, etc. to them with shackles, etc. 10) Apply wire ropes to the middle portion of the hook. q Slinging near the tip of the hook may cause the rope to slip off the hook during hoisting. The hook has the maximum strength at the middle por- tion. 11) Do not use twisted or kinked wire ropes. 12) When lifting up a load, observe the follow- ing. q Wind in the crane slowly until wire ropes are stretched. When settling the wire ropes with the hand, do not grasp them but press them from above. If you grasp them, your fingers may be caught. q After the wire ropes are stretched, stop the crane and check the condi- tion of the slung load, wire ropes, and pads.
  • 15. SEN05111-00 50-200 2 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel supply pump assembly Removal and installation of fuel supply pump assembly 1 Special tools Removal k Stop the machine on a level place and apply the parking brake. k Lower the work equipment to the ground and stop the engine. k Disconnect the cable from the negative (–) terminal of the battery. 1. Open fuel tank lower cover (1a). 2. Turn the fuel valve at the fuel tank bottom to the “CLOSE” position. 3. Open left engine side cover (1) and lock it. a Lock the cover securely. 4. Remove cover (2). 5. Remove 2 air conditioner hose clamps (3). 6. Remove air hose clamp (4) and disconnect air hose (5). [*1] 7. Remove 3 wiring harness clamps (6). 8. Disconnect wiring harness connectors CN-AC (7) and CN-ACG (8) and ground cable (9). 9. Remove air conditioner compressor (10). For details, see Testing and adjusting, “Testing and adjusting air conditioner compressor belt ten- sion”. [*2] a Fix air conditioner compressor (10) to the machine with a rope. 10. Disconnect wiring harness connector (11) from the fuel supply pump. 11. Remove hose clamp (12). 12. Disconnect overflow tube (13). [*3] Symbol Part No. Part name Necessity Q’ty New/Remodel Sketch A 1 795-799-1131 Gear t 1 2 795-799-1390 Remover t 1
  • 16. SEN05111-00 D65EX, PX, WX-16 50-200 3 200 Engine and cooling system Removal and installation of fuel supply pump assembly 13. Remove the fuel scatter prevention caps at both ends and disconnect fuel high-pressure pipe (14). [*4] 14. Disconnect fuel hoses (15), (16) and (17) according to the following procedure. [*5] 1) While pushing part (a) of fuel hose (15) in the direction of the arrow, pull part (b) in the direction of the arrow to disconnect the fuel hose. 2) Disconnect fuel hoses (16) and (17) simi- larly. 15. To remove the air conditioner hose clamp, remove the following covers. 1) Remove cover (18). 2) Remove left step cover (19). a Remove the cover in order to remove air conditioner hose clamp. 16. Remove hose clamp (20). 17. Disconnect wiring harness connector CN- AC05 (21). 18. Remove receiver drier and bracket assembly (22). a Fix receiver drier and bracket assembly (22) to the machine.
  • 17. SEN05111-00 50-200 4 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel supply pump assembly 19. Remove cap (23) from the flywheel housing and install engine cranking tool A1 (See the special tool table). a See Testing and adjusting, “Adjusting valve clearance”. 20. Loosen and remove cap (24). a Use a filter wrench etc. to remove cap (24). 21. Using tool A1, rotate the crankshaft forward (counterclockwise seeing from the flywheel side) and set stamp (M) of drive gear (GY) to the TDC (Top Dead Center). (See the special tool table) a Use a mirror to check the stamp etc. a See Testing and adjusting, “Adjusting valve clearance”. 22. Remove mounting nut (25) and washer (26) from fuel supply pump shaft (SH). a When removing mounting nut (25) and washer (26), take care not to drip them into the case. 23. Tighten tool A2 evenly to disconnect shaft (SH) of the fuel supply pump from drive gear (GY). 24. Remove bracket (27). 25. Remove 4 mounting nuts (28) and fuel supply pump assembly (29).
  • 18. SEN05111-00 D65EX, PX, WX-16 50-200 5 200 Engine and cooling system Removal and installation of fuel supply pump assembly Installation q Install the fuel supply pump assembly accord- ing to the following procedure. 1. Install fuel supply pump assembly (29) while matching projection (P) of its shaft (SH) to groove (G) of gear (GY). 2. Install bracket (27) to fuel supply pump assem- bly (29). 3 Mounting bolt (27a): 65 ± 6 Nm {6.6 ± 0.6 kgm} 3 Mounting bolt (27b): 77 ± 12 Nm {7.9 ± 1.2 kgm} 3. Install 4 mounting nuts (28). 2 Mounting nut (28): Adhesive (LT-2) 3 Mounting nut (28): 43 ± 6 Nm {4.4 ± 0.6 kgm} 4. Install washer (26) and tighten mounting nut (25). a When installing mounting nut (25) and washer (26), take care not to drip them into the case. 3 Mounting nut (25): 180 ± 13 Nm {18.4 ± 1.3 kgm} q Carry out the following installation in the reverse order to removal. [*1] a Push in air hose (5) to the stopper of the tube securely. 3 Air hose mounting clamp (4): 10.5 ± 0.5 Nm {1.07 ± 0.05 kgm} [*2] a Install the air conditioner compressor. For detail, see Testing and adjusting, “Testing and adjusting air conditioner compressor belt ten- sion” and “Removal and installation of air con- ditioner compressor”. [*3] 3 Overflow tube (13) mounting joint bolt: 24 ± 4 Nm {2.45 ± 0.41 kgm}
  • 19. SEN05111-00 50-200 6 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel supply pump assembly [*4] q Install fuel high-pressure pipe (14) and install the fuel scatter prevention caps to both ends. a Tighten the sleeve nut of fuel high-pressure pipe (14) with the fingers at first, and then tighten them permanently. 3 Fuel high-pressure pipe (14) sleeve nut: 37.3 ± 4 Nm {3.8 ± 0.4 kgm} [*5] k Since the internal parts of the installed por- tions of fuel hoses (15), (16) and (17) may have been damaged, replace those hoses with new ones. q Checking for fuel leakage (Fuel system) Check the fuel system for leakage. For details, see Testing and adjusting, “Checking fuel sys- tem for leakage”. q Bleeding air (Fuel system) Bleed air from the fuel circuit. For details, see Testing and adjusting, “Bleeding air from fuel circuit”.
  • 20. SEN05111-00 D65EX, PX, WX-16 50-200 7 200 Engine and cooling system Removal and installation of fuel injector assembly Removal and installation of fuel injector assembly 1 Special tools Removal k Stop the machine on a level place and apply the parking brake. k Lower the work equipment to the ground and stop the engine. k Disconnect the cable from the negative (–) terminal of the battery. 1. Open cover (1) under the fuel tank. 2. Turn the fuel valve at the fuel tank bottom to the “CLOSE” position. 3. Remove the engine hood assembly. For details, see “Removal and installation of engine hood assembly”. 4. Sling the muffler assembly temporarily. 5. Remove U-bolt (2) and mounting bolt (3). [*1] 6. Lift off muffler assembly (4). 4 Muffler assembly (4): 30 kg 7. Remove 3 air conditioner hose clamps (5). Symbol Part No. Part name Necessity Q’ty New/Remodel Sketch A 1 795-799-1131 Gear t 1 3 795-799-6700 Puller t 1 4 795-799-8150 Remover q 1
  • 21. SEN05111-00 50-200 8 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel injector assembly 8. Remove wiring harness clamp (6). 9. Disconnect wiring harness connectors CN-AC (7) and CN-ACG (8) and ground cable (9). 10. Remove air conditioner compressor assembly (10). For details, see Testing and adjusting, “Testing and adjusting air conditioner compres- sor belt tension”. [*2] a Fix air conditioner compressor assembly (10) to the machine with a rope. 11. Remove tube clamp (11) and muffler water drain tube (12). 12. Remove bracket (13). 13. Remove wiring harness clamps (14), (15) and (16). 14. Disconnect the following wiring harness con- nectors. (17): CN-HTD (Disconnect from clamp) (18): CN-WIF (19): CN-HT/B (20): CN-HT/A (21): CN-HT/C (22): Ground 15. Remove plate (23). 16. Remove hose clamp (24) and disconnect air hose (25). [*3] 17. Disconnect wiring harness connectors CN-C8 (26) and CN-C17 (27). 18. Disconnect air tube (29). [*4]
  • 22. SEN05111-00 D65EX, PX, WX-16 50-200 9 200 Engine and cooling system Removal and installation of fuel injector assembly 19. Remove left step cover (30). a Remove the left step cover to remove the air conditioner hose clamp. 20. Remove hose clamp (31). 21. Disconnect wiring harness connector CN- AC05 (32). 22. Remove receiver drier and bracket assembly (33). a Fix receiver drier and bracket assembly (33) to the machine. 23. Disconnect 2 heater hoses (34). 24. Disconnect 2 fuel hoses (35). [*5] a While pushing part (c) of fuel hose (35) in the direction of the arrow, pull part (d) in the direction of the arrow to disconnect the fuel hose. 25. Remove fuel filter and corrosion resistor assembly (36). 26. Disconnect wiring harness connector CN-C4 (37). a To disconnect wiring harness connector CN-C4 (37), slide lock (e) in the direction of the arrow and pull the connector toward you while pressing lock (f). a Even if lock (f) is pressed, the connector cannot be pulled out if part (g) does not float. In this case, float part (g) with a flat- head screwdriver while pressing lock (f) and pull out the connector toward you to disconnect.
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  • 24. SEN05111-00 50-200 10 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel injector assembly 27. Remove bracket (38). 28. Remove wiring harness clamp (39). 29. Disconnect 3 fuel injector wiring harness con- nectors CN-C9 (41). 30. Remove bracket (42). 31. Remove the fuel scatter prevention caps at both ends and disconnect 6 fuel high-pressure pipes (43). [*6] 32. Remove hose clamp (44) and disconnect 2 blow-by hoses (45). 33. Remove cylinder head cover (46). [*7]
  • 25. SEN05111-00 D65EX, PX, WX-16 50-200 11 200 Engine and cooling system Removal and installation of fuel injector assembly 34. Loosen 2 capture nuts (47) at the fuel injector head and disconnect fuel injector wiring har- ness (48). a Loosen the capture nuts alternately. a The capture nuts are not removable from the wiring harness. a Installed position of wiring harness 35. Loosen locknut (49) and loosen adjustment screw (50) by 2 – 3 turns. a Loosen the adjustment screw so that an excessive force will not be applied to the pushrod when the rocker arm is installed. 36. Remove mounting bolts (51) and rocker arm and crosshead assembly (52). a Record the installed position and direction (shapes of holes (a) and (b)) of the cross- head. (Install the crosshead in the recorded direction) 37. Remove retainer (53) and inlet connector (54). a Before removing retainer (53), remove all dirt and sand sticking to and around the retainer. a Tool A4 (remover) is set for removing inlet connector (54). (See the special tool table) 38. Remove 2 fuel injector holder mounting bolts (55). 39. Using tool A3, remove fuel injector holder (56) and fuel injector assembly (57) together. a Take care that dirt and foreign matter will not enter the mounting portion of fuel injector assembly (57). a Never hold the solenoid valve at the fuel injector top with pliers etc. Cable color Cylinder No. p Yellow May be installed reversely 1, 3, 5 q Orange r Red May be installed reversely 2, 4, 6 s Brown
  • 26. SEN05111-00 50-200 12 D65EX, PX, WX-16 200 Engine and cooling system Removal and installation of fuel injector assembly Installation q Fuel injector assembly a Check that the fuel injector installation hole is free from flaw and dirt. a When replacing the fuel injector assembly with new one, be sure to replace the inlet connec- tor, too. a Check the inlet connector visually for the fol- lowing defects. If it has any of those defects, replace it with new one. (a): There are burrs or deformation at the inlet or outlet of the inlet connector. (b): The edge filter is clogged or dirty. If there is sediment in it, it must not be reused. (c): The O-ring is cracked or deteriorated. (d): The outlet seal surface is worn or has a trace of bad contact or leakage. a If high-pressure fuel leaks, the seat surface is eroded and fine streaks or cracks are made. In this case, replace the inlet connector and fuel injector assembly with new ones. 1. Install gasket (58) and O-ring (59) to fuel injec- tor assembly (57). 2 O-ring (59) and fuel injector mounting hole: Engine oil (EO15W-40) 2. Install fuel injector holder (56) to fuel injector assembly (57). a Match the convex (A) and concave (B) parts. 3. Insert fuel injector assembly (57) in the cylin- der head with its fuel inlet hole directed toward the intake manifold. 4. Finger-tighten mounting bolts (55) of fuel injec- tor holder (56) 3 – 4 turns. 5. Install inlet connector (54) with retainer (53) temporarily. 2 O-ring of inlet connector (54) and mounting hole on cylinder head side: Engine oil (EO15W-40) 3 Retainer (53): 15 ± 5.0 Nm {1.5 ± 0.5 kgm} 6. Tighten mounting bolts (55) of fuel injector holder (56) alternately. 3 Fuel injector holder mounting bolt (55): 10 ± 2 Nm {1.0 ± 0.2 kgm} a The top of fuel injector holder (56) must be in parallel with the top of the cylinder head. Max. allowance: 2.4°