Komatsu D65px 17 Shop Manual

Full download: http://manualplace.com/download/komatsu-d65px-17-shop-manual/

SEN05536-01

BULLDOZER D65EX -17

D65PX -17
D65WX -17
D65EX- 1001
SERIAL NUMBERS D65PX- 1001 and up
D65WX-1001

This is the cut pages sample. Download all 1848 page(s) at: ManualPlace.com
Shop Manual

Bulldozer
D65EX-17 D65PX-
17 D65WX-17
Model Serial Number

D65EX-17 1001 and up

D65PX-17
D65WX-17

00 Index and foreword

1 00 Index and foreword

D65EX,PX,WX-17 00-1
00 Index and foreword
Index

Index
00 Index and foreword ....................................................................................................................... 00-1
Index ......................................................................................................................................... 00-2
Foreword, safety and general information ................................................................................... 00-15
Important safety notice ....................................................................................................... 00-15
How to read the shop manual.............................................................................................. 00-20
Explanation of terms for maintenance standard .................................................................... 00-22
Handling of fuel system devices .......................................................................................... 00-24
Handling of intake system parts........................................................................................... 00-25
Handling of hydraulic equipment.......................................................................................... 00-26
Method of disconnecting and connecting push-pull type coupler............................................. 00-28
Handling of electrical equipment.......................................................................................... 00-31
How to read electric wire code............................................................................................. 00-39
Precautions when performing operation ............................................................................... 00-42
Standard tightening torque table.......................................................................................... 00-45
List of abbreviation ............................................................................................................. 00-49
Conversion table ................................................................................................................ 00-53
01 Specification................................................................................................................................. 01-2
Specifications............................................................................................................................. 01-3
Specification drawing ........................................................................................................... 01-3
Specifications ...................................................................................................................... 01-6
Weight table ...................................................................................................................... 01-30
Table of fuel, coolant and lubricants ..................................................................................... 01-38
10 Structure and function ................................................................................................................... 10-3
Engine and cooling system .......................................................................................................... 10-4
Engine related parts ............................................................................................................. 10-4
Damper ............................................................................................................................... 10-6
Cooling system .................................................................................................................... 10-8
Cooling fan pump ............................................................................................................... 10-10
Cooling fan motor............................................................................................................... 10-24
Power train............................................................................................................................... 10-32
Power train ........................................................................................................................ 10-32
HSS system ...................................................................................................................... 10-35
Overall drawing of power train unit ....................................................................................... 10-37
Power train mount .............................................................................................................. 10-39
Power train hydraulic piping drawing.................................................................................... 10-40
Transmission, steering, and brake control ............................................................................ 10-42
Universal joint .................................................................................................................... 10-44
Torque converter and PTO .................................................................................................. 10-45
Transmission ..................................................................................................................... 10-51
Transmission control valve.................................................................................................. 10-64
Forward and reverse clutch ECMV and gear shift clutch ECMV .............................................. 10-66
Lockup clutch ECMV .......................................................................................................... 10-73
Main relief valve and torque converter relief valve ................................................................. 10-77
Transmission lubricating oil relief valve ................................................................................ 10-80
Bevel gear shaft, HSS, and brake ........................................................................................ 10-81
Brake valve ..................................................................................................................... 10-102
Final drive ....................................................................................................................... 10-106
Undercarriage and frame......................................................................................................... 10-110
Main frame ...................................................................................................................... 10-110
Suspension ..................................................................................................................... 10-112
Track frame and idler cushion ........................................................................................... 10-114
Hydraulic system .................................................................................................................... 10-116
Hydraulic piping drawing................................................................................................... 10-116
Work equipment control .................................................................................................... 10-120
Hydraulic tank.................................................................................................................. 10-122
CLSS .............................................................................................................................. 10-124
Scavenging pump ............................................................................................................ 10-127

00-2 D65EX,PX,WX-17
 00 Index and foreword
Index

Steering lubricating oil pump and power train pump............................................................. 10-128

HSS pump....................................................................................................................... 10-129
HSS motor ...................................................................................................................... 10-150
Control valve ................................................................................................................... 10-159
Blade PPC valve .............................................................................................................. 10-186
Ripper PPC valve............................................................................................................. 10-194
Quick drop valve .............................................................................................................. 10-198
Work equipment lock solenoid valve .................................................................................. 10-201
Pitch selector solenoid valve ............................................................................................. 10-206
Angle control EPC valve ................................................................................................... 10-207
Hydraulic oil cooler bypass valve ....................................................................................... 10-212
PPC accumulator ............................................................................................................. 10-213
Work equipment ..................................................................................................................... 10-214
Work equipment............................................................................................................... 10-214
Ripper ............................................................................................................................. 10-217
Piston valve..................................................................................................................... 10-218
Cab and its attachments .......................................................................................................... 10-220
ROPS cab ....................................................................................................................... 10-220
Cab mount ...................................................................................................................... 10-222
Electrical system .................................................................................................................... 10-223
Engine control system ...................................................................................................... 10-223
Cooling system control system .......................................................................................... 10-226
Palm command control system.......................................................................................... 10-228
Machine monitor system ................................................................................................... 10-232
KOMTRAX system ........................................................................................................... 10-252
System component part.................................................................................................... 10-255
Sensors .......................................................................................................................... 10-270
20 Standard value table ..................................................................................................................... 20-2
Standard service value table........................................................................................................ 20-3
Standard value table for engine ............................................................................................. 20-3
Standard value table for machine .......................................................................................... 20-5
30 Testing and adjusting .................................................................................................................... 30-3
General information on testing and adjusting................................................................................. 30-4
Tools for testing, adjusting, and troubleshooting ...................................................................... 30-4
Engine and cooling system .......................................................................................................... 30-8
Testing engine speed ........................................................................................................... 30-8
Measuring boost pressure................................................................................................... 30-10
Measuring exhaust gas temperature .................................................................................... 30-11
Measuring exhaust gas color............................................................................................... 30-13
Measuring and adjusting valve clearance ............................................................................. 30-15
Measuring compression pressure ........................................................................................ 30-17
Measuring blowby pressure ................................................................................................ 30-19
Measuring engine oil pressure............................................................................................. 30-21
Measuring EGR valve and KVGT oil pressure....................................................................... 30-22
Releasing remaining pressure from fuel system .................................................................... 30-23
Measuring fuel pressure ..................................................................................................... 30-24
Measuring fuel delivery, return rate and leakage ................................................................... 30-31
Handling cylinder cutout mode operation.............................................................................. 30-35
Handling no injection cranking operation .............................................................................. 30-36
Bleeding air from fuel system .............................................................................................. 30-37
Checking fuel circuit for leakage .......................................................................................... 30-38
Testing and adjusting air conditioner compressor belt tension ................................................ 30-39
Replacing alternator belt ..................................................................................................... 30-40
Adjusting fuel dial and decelerator pedal .............................................................................. 30-41
Power train system ................................................................................................................... 30-43
Measuring power train oil pressure ...................................................................................... 30-43
Adjusting transmission output shaft speed sensor (replacement procedure) ............................ 30-48
Simple test procedure for brake performance ....................................................................... 30-49
Adjusting brake pedal ......................................................................................................... 30-50

D65EX,PX,WX-17 00-3
00 Index and foreword
Index

Adjusting parking brake lever .............................................................................................. 30-52

Retrieval of disabled machine using brake release device ..................................................... 30-54
Undercarriage and frame........................................................................................................... 30-57
Adjusting idler clearance..................................................................................................... 30-57
Checking sprocket wear ..................................................................................................... 30-58
Checking and adjusting track shoe tension........................................................................... 30-59
Hydraulic system ...................................................................................................................... 30-60
Releasing remaining pressure in work equipment cylinder ..................................................... 30-60
Measuring and adjusting work equipment and HSS oil pressure............................................. 30-61
Measuring source pressure of control circuit ......................................................................... 30-64
Measuring PPC valve output pressure ................................................................................. 30-65
Adjusting play of work equipment PPC valve ........................................................................ 30-68
Isolating the parts causing hydraulic drift in blade and ripper .................................................. 30-70
Measure internal oil leakage of work equipment cylinder........................................................ 30-71
Checking fan speed ........................................................................................................... 30-72
Measuring fan circuit oil pressure ........................................................................................ 30-73
Bleeding air from hydraulic circuit ........................................................................................ 30-74
Work equipment ....................................................................................................................... 30-76
Adjusting work equipment lock lever .................................................................................... 30-76
Adjustment of straight tilt dozer............................................................................................ 30-77
Cab and its attachments ............................................................................................................ 30-79
Adjusting operator's cab ..................................................................................................... 30-79
Adjusting play of blade center ball........................................................................................ 30-82
Electrical system ...................................................................................................................... 30-83
Special functions of machine monitor ................................................................................... 30-83
Handling voltage circuit of engine controller........................................................................ 30-143
Adjustment method when controller has been replaced ....................................................... 30-144
Testing diodes ................................................................................................................. 30-146
Pm clinic ................................................................................................................................ 30-147
Pm Clinic service ............................................................................................................. 30-147
Pm Clinic check sheet ...................................................................................................... 30-153
40 Troubleshooting............................................................................................................................ 40-8
General information on troubleshooting ........................................................................................ 40-9
Instruction on troubleshooting ............................................................................................... 40-9
How to proceed troubleshooting .......................................................................................... 40-11
Check before troubleshooting.............................................................................................. 40-12
Testing procedure before troubleshooting............................................................................. 40-14
Classification and procedure for troubleshooting ................................................................... 40-23
Classification and procedures for troubleshooting numbers.................................................... 40-25
Information mentioned in troubleshooting table ..................................................................... 40-28
Troubleshooting method for open circuit in wiring harness of pressure sensor system .............. 40-30
Connector list and layout .................................................................................................... 40-32
Connector contact identification........................................................................................... 40-45
T-branch box and T-branch adapter table ............................................................................. 40-82
Fuse locations table ........................................................................................................... 40-88
Precautions for cleaning and replacing KDPF (KCSF, KDOC) ................................................ 40-91
Troubleshooting by failure code (Display of code) ........................................................................ 40-93
Failure codes table............................................................................................................. 40-93
Failure code [1500L0] Transmission clutch:Abnormal.......................................................... 40-104
Failure code [15SAL1] Forward clutch:Fill High................................................................... 40-105
Failure code [15SALH] Forward clutch:Fill Low ................................................................... 40-107
Failure code [15SBL1] Reverse clutch:Fill High................................................................... 40-109
Failure code [15SBLH] Reverse clutch:Fill Low....................................................................40-111
Failure code [15SEL1] Speed 1st clutch:Fill High ................................................................ 40-113
Failure code [15SELH] Speed 1st clutch:Fill Low ................................................................ 40-115
Failure code [15SFL1] Speed 2nd clutch:Fill High ............................................................... 40-117
Failure code [15SFLH] Speed 2nd clutch:Fill Low ............................................................... 40-119
Failure code [15SGL1] Speed 3rd clutch:Fill High ............................................................... 40-121
Failure code [15SGLH] Speed 3rd clutch:Fill Low................................................................ 40-123

00-4 D65EX,PX,WX-17
 00 Index and foreword
Index

Failure code [15SJL1] L/U :Fill Hihg ................................................................................... 40-125

Failure code [15SJLH] L/U :Fill low .................................................................................... 40-127
Failure code [1800MW] P/L clutch:Slip ............................................................................... 40-129
Failure code [879AKA] Air Conditioner Inner Sensor Disconnection...................................... 40-130
Failure code [879AKB] Air Conditioner Inner Sensor Disconnection...................................... 40-131
Failure code [879BKA] Air Conditioner Outside Air Sensor Disconnection ............................. 40-132
Failure code [879BKB] Air Conditioner Outside Air Sensor Disconnection ............................. 40-133
Failure code [879CKA] Ventilating Sensor Disconnection .................................................... 40-134
Failure code [879CKB] Ventilating Sensor Short Circuit ....................................................... 40-135
Failure code [879DKZ] Sunlight Sensor Open Or Short Circuit ............................................. 40-136
Failure code [879EMC] Ventilation Abnormal ...................................................................... 40-137
Failure code [879FMC] A/M Damper Abnormal ................................................................... 40-138
Failure code [879GKX] Refrigerant Abnormality .................................................................. 40-139
Failure code [989L00] Engine Controller Lock Caution 1...................................................... 40-140
Failure code [989M00] Engine Controller Lock Caution 2..................................................... 40-141
Failure code [989N00] Engine Controller Lock Caution 3 ..................................................... 40-142
Failure code [A1U0N3]: KDPF Dry Request (HC Release)................................................... 40-143
Failure code [A1U0N4] KDPF Dry Request (HC Release).................................................... 40-145
Failure code [AA10NX] Air Cleaner Clogging ...................................................................... 40-147
Failure code [AB00KE] Battery Charge Voltage Low ........................................................... 40-148
Failure code [B@BAZG] Engine Oil Pressure Low .............................................................. 40-150
Failure code [B@BCNS] Eng Water Overheat .................................................................... 40-151
Failure code [B@CENS] P/L Oil Overheat .......................................................................... 40-152
Failure code [B@HANS] Hyd Oil Overheat ......................................................................... 40-153
Failure code [CA115] Eng Ne and Bkup Speed Sens Error .................................................. 40-154
Failure code [CA122] Chg Air Press Sensor High Error ....................................................... 40-155
Failure code [CA123] Chg Air Press Sensor Low Error ........................................................ 40-157
Failure code [CA131] Throttle Sensor High Error................................................................. 40-159
Failure code [CA132] Throttle Sensor Low Error ................................................................. 40-161
Failure code [CA144] Coolant Temp Sens High Error .......................................................... 40-163
Failure code [CA145] Coolant Temp Sens Low Error ........................................................... 40-165
Failure code [CA153] Chg Air Temp Sensor High Error ........................................................ 40-167
Failure code [CA154] Chg Air Temp Sensor Low Error......................................................... 40-169
Failure code [CA187] Sensor 2 Supply Volt Low Error ......................................................... 40-171
Failure code [CA234] Eng Overspeed ................................................................................ 40-173
Failure code [CA221] Ambient Press Sens High Error ......................................................... 40-174
Failure code [CA222] Ambient Press Sens Low Error .......................................................... 40-176
Failure code [CA227] Sens Supply 2 Volt High Error ........................................................... 40-178
Failure code [CA238] Ne Speed Sens Supply Volt Error ...................................................... 40-179
Failure code [CA239] Ne Speed Sens Supply Volt High Error............................................... 40-180
Failure code [CA271] IMV/PCV1 Short Error ...................................................................... 40-182
Failure code [CA272] IMV/PCV1 Open Error ...................................................................... 40-184
Failure code [CA281] Pump Press Balance Error ................................................................ 40-186
Failure code [CA295] Ambient Pressure Sensor In Range Error ........................................... 40-187
Failure code [CA322] Inj #1(L#1) Open/Short Error ............................................................. 40-188
Failure code [CA323] Inj #5 (L#5) Open/Short Error ............................................................ 40-190
Failure code [CA324] Inj #3(L#3) Open/Short Error ............................................................. 40-192
Failure code [CA325] Inj #6 (L#6) Open/Short Error ............................................................ 40-194
Failure code [CA331] Inj #2(L#2) Open/Short Error ............................................................. 40-196
Failure code [CA332] Inj #4 (L#4) Open/Short Error ............................................................ 40-198
Failure code [CA343] ECM Critical Internal Failure.............................................................. 40-200
Failure code [CA351] Injectors Drive Circuit Error ............................................................... 40-201
Failure code [CA352] Sensor 1 Supply Volt Low Error ......................................................... 40-202
Failure code [CA356] Mass Air Flow Sensor High Error ....................................................... 40-204
Failure code [CA357] Mass Air Flow Sensor Low Error ........................................................ 40-206
Failure code [CA386] Sens Supply 1 Volt High Error ........................................................... 40-208
Failure code [CA428] Water in Fuel Sensor High Error ........................................................ 40-209
Failure code [CA429] Water in Fuel Sensor Low Error ......................................................... 40-211
Failure code [CA435] Eng Oil Press SW Error .................................................................... 40-213

D65EX,PX,WX-17 00-5
00 Index and foreword
Index

Failure code [CA441] Battery Voltage Low Error ................................................................. 40-214

Failure code [CA442] Battery Voltage High Error................................................................. 40-216
Failure code [CA449] Rail Press Very High Error................................................................. 40-217
Failure code [CA451] Rail Press Sensor High Error............................................................. 40-219
Failure code [CA452] Rail Press Sensor Low Error ............................................................. 40-221
Failure code [CA488] Chg Air Temp High Torque Derate...................................................... 40-223
Failure code [CA515] Rail Press Sens Sup Volt High Error .................................................. 40-224
Failure code [CA516] Rail Press Sens Sup Volt Low Error ................................................... 40-226
Failure code [CA553] Rail Press High Error ........................................................................ 40-228
Failure code [CA555] Crankcase Press High Error 2 ........................................................... 40-229
Failure code [CA556] Crankcase Pressure High Error 3 ...................................................... 40-230
Failure code [CA559] Rail Pump Press Low Error ............................................................... 40-231
Failure code [CA595] Turbocharger Speed High Error 2 ...................................................... 40-235
Failure code [CA687] Turbo Speed Low Error ..................................................................... 40-236
Failure code [CA689] Eng Ne Speed Sensor Error .............................................................. 40-238
Failure code [CA691] Intake Air Temp Sens High Error ........................................................ 40-242
Failure code [CA692] Intake Air Temp Sens Low Error......................................................... 40-244
Failure code [CA697] ECM Internal Temp Sensor High Error................................................ 40-246
Failure code [CA698] ECM Internal Temp Sensor Low Error ................................................ 40-247
Failure code [CA731] Eng Bkup Speed Sens Phase Error ................................................... 40-248
Failure code [CA778] Eng Bkup Speed Sensor Error........................................................... 40-250
Failure code [CA1117] Engine Controller Partial Data Lost Error........................................... 40-255
Failure code [CA1664] KDOC Malfunction.......................................................................... 40-256
Failure code [CA1691] Regeneration Ineffective ................................................................. 40-258
Failure code [CA1695] Sensor 5 Supply Volt High Error....................................................... 40-261
Failure code [CA1696] Sensor 5 Supply Volt Low Error ....................................................... 40-262
Failure code [CA1843] Crankcase Press Sens High Error.................................................... 40-264
Failure code [CA1844] Crankcase Press Sens Low Error .................................................... 40-266
Failure code [CA1879] KDPF Delta P Sensor High Error ..................................................... 40-268
Failure code [CA1881] KDPF Delta P Sensor Low Error ...................................................... 40-270
Failure code [CA1883] KDPF Delta P Sens In Range Error.................................................. 40-272
Failure code [CA1921] KDPF Soot Level High Error 1 ......................................................... 40-275
Failure code [CA1922] KDPF Soot Level High Error 2 ......................................................... 40-277
Failure code [CA1942] Crankcase Press Sensor In Range Error .......................................... 40-281
Failure code [CA1993] KDPF Delta Pressure Low Error ...................................................... 40-282
Failure code [CA2185] Throt Sensor Sup Volt High Error ..................................................... 40-283
Failure code [CA2186] Throt Sensor Sup Volt Low Error...................................................... 40-285
Failure code [CA2249] Rail Press Very Low Error ............................................................... 40-287
Failure code [CA2265] Fuel Feed Pump Open Error............................................................ 40-288
Failure code [CA2266] Fuel Feed Pump Short Error ............................................................ 40-290
Failure code [CA2271] EGR Valve Pos Sens High Error ...................................................... 40-292
Failure code [CA2272] EGR Valve Pos Sens Low Error ....................................................... 40-294
Failure code [CA2288] Turbo Speed High Error 1................................................................ 40-297
Failure code [CA2311] lMV Solenoid Error.......................................................................... 40-298
Failure code [CA2349] EGR Valve Solenoid Open Error ...................................................... 40-299
Failure code [CA2353] EGR Valve Solenoid Short Error ...................................................... 40-301
Failure code [CA2357] EGR Valve Servo Error ................................................................... 40-303
Failure code [CA2373] Exhaust Manifold Press Sens High error........................................... 40-304
Failure code [CA2374] Exhaust Manifold Press Sens Low error ........................................... 40-306
Failure code [CA2375] EGR Orifice Temp Sens High Error .................................................. 40-308
Failure code [CA2376] EGR Orifice Temp Sens Low Error ................................................... 40-310
Failure code [CA2381] KVGT Pos Sens High Error ............................................................. 40-312
Failure code [CA2382] KVGT Pos Sens Low Error .............................................................. 40-314
Failure code [CA2383] KVGT Solenoid Open Error ............................................................. 40-316
Failure code [CA2386] KVGT Solenoid Short Error ............................................................. 40-318
Failure code [CA2387] KVGT Valve Servo Error ................................................................. 40-320
Failure code [CA2554] Exh Manifold Press Sens In Range error .......................................... 40-321
Failure code [CA2555] Grid Htr Relay Volt Low Error ........................................................... 40-322
Failure code [CA2556] Grid Htr Relay Volt High Error .......................................................... 40-324

00-6 D65EX,PX,WX-17
 00 Index and foreword
Index

Failure code [CA2637] KDOC Blocked............................................................................... 40-326

Failure code [CA2639] Manual Stationary Regeneration Request......................................... 40-328
Failure code [CA2961] EGR Orifice Temp High Error 1 ........................................................ 40-331
Failure code [CA2973] Chg Air Press Sensor In Range Error ............................................... 40-332
Failure code [CA3133] KDPF Outlet Press Sens High Error ................................................. 40-333
Failure code [CA3134] KDPF Outlet Press Sens Low Error.................................................. 40-335
Failure code [CA3135] KDPF Outlet Press Sens In Range Error .......................................... 40-337
Failure code [CA3251] KDOC Inlet Temp High Error............................................................ 40-340
Failure code [CA3253] KDOC Temp Error - Non Regeneration............................................. 40-343
Failure code [CA3254] KDOC Outlet Temp High Error 1 ...................................................... 40-344
Failure code [CA3255] KDPF Temp Error - Non Regeneration.............................................. 40-347
Failure code [CA3256] KDPF Outlet Temp High Error 1 ....................................................... 40-348
Failure code [CA3311] KDOC Outlet Temp High Error 2....................................................... 40-349
Failure code [CA3312] KDPF Outlet Temp High Error 2 ....................................................... 40-350
Failure code [CA3313] KDOC Inlet Temp Sensor Low Error ................................................. 40-353
Failure code [CA3314] KDOC Inlet Temp Sens High Error ................................................... 40-356
Failure code [CA3315] KDOC Inlet Temp Sens In Range Error............................................. 40-360
Failure code [CA3316] KDOC Outlet Temp Sens Low Error ................................................. 40-364
Failure code [CA3317] KDOC Outlet Temp Sens High Error................................................. 40-367
Failure code [CA3318] KDOC Outlet Temp Sens In Range Error .......................................... 40-371
Failure code [CA3319] KDPF Outlet Temp Sens High Error ................................................. 40-375
Failure code [CA3321] KDPF Outlet Temp Sens Low Error .................................................. 40-379
Failure code [CA3322] KDPF Outlet Temp Sens In Range Error........................................... 40-382
Failure code [CA3419] Mass Air Flow Sensor Sup Volt High Error ........................................ 40-386
Failure code [CA3421] Mass Air Flow Sensor Sup Volt Low Error ......................................... 40-388
Failure code [CA3741] Rail Press Valve Trip Error............................................................... 40-390
Failure code [D130KA] Neutral relay:Open ......................................................................... 40-391
Failure code [D130KB] Neutral relay:Short circuit................................................................ 40-393
Failure code [D19DKA] Amber light relay:Open .................................................................. 40-395
Failure code [D19DKB] Amber light relay:Short circuit ......................................................... 40-397
Failure code [D19JKZ] Personal Code Relay Abnormality.................................................... 40-399
Failure code [D811MC] KOMTRAX Error............................................................................ 40-402
Failure code [D862KA] GPS Antenna Open Circuit ............................................................. 40-403
Failure code [D8ALKA] Operating Lamp Open Circuit(KOMTRAX) ....................................... 40-404
Failure code [D8ALKB] Operating Lamp Short Circuit(KOMTRAX) ....................................... 40-406
Failure code [D8AQKR] CAN2 Discon(KOMTRAX) ............................................................. 40-407
Failure code [DAF0MB] Monitor Memory Error.................................................................... 40-408
Failure code [DAF0MC] Monitor Malfunction....................................................................... 40-409
Failure code [DAF8KB] Camera Power Supply Short Circuit ................................................ 40-410
Failure code [DAF9KQ] Model Selection Abnormality .......................................................... 40-412
Failure code [DAFGMC] GPS Module Error........................................................................ 40-413
Failure code [DAFLKA] Operating Lamp Open Circuit(Monitor) ............................................ 40-414
Failure code [DAFLKB] Operating Lamp Short Circuit(Monitor) ............................................ 40-416
Failure code [DAFQKR] CAN2 Discon ............................................................................... 40-417
Failure code [DAZ9KQ] A/C Model Selection Abnormality.................................................... 40-418
Failure code [DAZQKR] CAN2 Discon (Aircon ECU) ........................................................... 40-419
Failure code [DB2QKR] CAN2 Discon (Engine Con) ........................................................... 40-423
Failure code [DB2RKR] CAN1 Discon (Engine Con) ........................................................... 40-428
Failure code [DBE0KT] PT controller:Abnormality in controller.............................................. 40-433
Failure code [DBE1KK] PT controller:Source voltage low..................................................... 40-434
Failure code [DBE2KK] PT controller:Output voltage low ..................................................... 40-436
Failure code [DBE5KK] PT:Sensor volt 5V (0) Out of normal range ....................................... 40-438
Failure code [DBE6KK] PT:Sensor volt 24V Out of normal range .......................................... 40-440
Failure code [DBE7KK] PT:Sensor volt 5V (1) Out of normal range ....................................... 40-442
Failure code [DBE9KQ] PT controller:Type select signal ...................................................... 40-444
Failure code [DBELKA] Operating Lamp Open Circuit(PT Con)............................................ 40-445
Failure code [DBELKB] Operating Lamp Short Circuit(PT Con) ............................................ 40-447
Failure code [DBEQKR] CAN2 Discon (PT Con) ................................................................. 40-448
Failure code [DBERKR] CAN1 Discon (PT Con) ................................................................. 40-449

D65EX,PX,WX-17 00-7
00 Index and foreword
Index

Failure code [DD12KA] Shift up Sw:Open .......................................................................... 40-450

Failure code [DD12KB] Shift up Sw:Short circuit ................................................................. 40-452
Failure code [DD13KA] Shift down Sw:Open ...................................................................... 40-454
Failure code [DD13KB] Shift down Sw:Short circuit ............................................................. 40-456
Failure code [DD14KA] Parking lever Sw:Open .................................................................. 40-458
Failure code [DD14KB] Parking lever Sw:Short circuit ......................................................... 40-460
Failure code [DDKFL4] Left Angle Sw:Signal mismatch ....................................................... 40-462
Failure code [DDKGL4] Right Angle Sw:Signal mismatch .................................................... 40-464
Failure code [DDKHKA] iB Sw:Open.................................................................................. 40-466
Failure code [DDKHKB] iB Sw:Short circuit ........................................................................ 40-468
Failure code [DDN7KA] Weq pitch SW: Open ..................................................................... 40-470
Failure code [DDN7KB] Pitch select solenoid:Short circuit ................................................... 40-472
Failure code [DDNLKA] Weq lock Sw:Open ....................................................................... 40-474
Failure code [DDNLKB] Weq lock Sw:Short circuit .............................................................. 40-476
Failure code [DGS1KA] Hyd oil temp sensor:Open ............................................................. 40-478
Failure code [DGS1KX] Hyd oil temp: signal abnormal ........................................................ 40-479
Failure code [DGT1KA] T/C oil temp sensor:Open .............................................................. 40-481
Failure code [DGT1KX] T/C oil temp sensor:Out of normal range ......................................... 40-482
Failure code [DH21KA] Weq pressure sensor:Open............................................................ 40-484
Failure code [DH21KB] Work equipment pressure sensor:Hot Short..................................... 40-486
Failure code [DHA4KA] Air Cleaner Clogging Sensor Open Circuit ....................................... 40-488
Failure code [DHTDKA] T/C pressure sensor:Open............................................................. 40-489
Failure code [DHTDKB] T/C pressure sensor:Hot Short....................................................... 40-491
Failure code [DK10KA] Fuel control Dial:Open ................................................................... 40-493
Failure code [DK10KB] Fuel control Dial:Short circuit .......................................................... 40-495
Failure code [DK30KA] ST lever1:Open ............................................................................. 40-497
Failure code [DK30KB] ST lever:Hot Short ......................................................................... 40-499
Failure code [DK30KX] ST lever:Main and Sub Error........................................................... 40-501
Failure code [DK30KZ] ST lever:Main and Sub Error ........................................................... 40-502
Failure code [DK30L8] ST lever:Signal mismatch................................................................ 40-503
Failure code [DK31KA] ST lever2:Open ............................................................................. 40-504
Failure code [DK31KB] ST lever2:Hot Short ....................................................................... 40-506
Failure code [DK40KA] Brake potentiometer:Open.............................................................. 40-508
Failure code [DK40KB] Brake potentiometer:Hot Short........................................................ 40-510
Failure code [DK55KX] FR lever:Main and Sub Error .......................................................... 40-512
Failure code [DK55KZ] FR lever:Main and Sub Error........................................................... 40-513
Failure code [DK55L8] FR lever:Signal mismatch ............................................................... 40-514
Failure code [DK56KA] FR lever1:Open ............................................................................. 40-515
Failure code [DK56KB] FR lever1:Hot Short ....................................................................... 40-517
Failure code [DK57KA] FR lever2:Open ............................................................................. 40-519
Failure code [DK57KB] FR lever2:Hot Short ....................................................................... 40-521
Failure code [DKH1KA] Pitch angle sensor:Open................................................................ 40-523
Failure code [DKH1KB] Pitch angle sensor:Hot Short.......................................................... 40-525
Failure code [DLM3KA] Fan rev. sensor:Open .................................................................... 40-527
Failure code [DLM3MB] Fan control:Mismatch.................................................................... 40-529
Failure code [DLT3KA] T/M out-speed sensor:Open............................................................ 40-530
Failure code [DLT3KB] T/M out-speed sensor:Short circuit .................................................. 40-532
Failure code [DV20KB] Back-up alarm :Short Circuit ........................................................... 40-533
Failure code [DW5AKA] Pitch select solenoid:Disconnection ............................................... 40-535
Failure code [DW5AKB] Pitch select solenoid:Short circuit................................................... 40-536
Failure code [DW5AKY] Pitch select solenoid:Hot short....................................................... 40-537
Failure code [DW7BKA] Fan reverse solenoid:Open ........................................................... 40-539
Failure code [DW7BKB] Fan reverse solenoid:Short circuit .................................................. 40-541
Failure code [DWN1KA] Hss EPC RH:Open....................................................................... 40-542
Failure code [DWN1KB] Hss EPC RH:Short circuit ............................................................. 40-543
Failure code [DWN1KY] Hss EPC RH:Hot short ................................................................. 40-544
Failure code [DWN2KA] Hss EPC LH:Open ....................................................................... 40-546
Failure code [DWN2KB] Hss EPC LH:Short circuit .............................................................. 40-547
Failure code [DWN2KY] Hss EPC LH:Hot short .................................................................. 40-548

00-8 D65EX,PX,WX-17
 00 Index and foreword
Index

Failure code [DWN5KA] Fan pump solenoid 1 :Open .......................................................... 40-550

Failure code [DWN5KB] Fan pump solenoid 1 :Short circuit ................................................. 40-551
Failure code [DWN5KY] Fan pump solenoid 1: Hot short ..................................................... 40-552
Failure code [DXA2KA] TVC solenoid 1: Open ................................................................... 40-554
Failure code [DXA2KB] TVC solenoid 1: Short circuit .......................................................... 40-555
Failure code [DXA2KY] TVC solenoid 1: Hot short .............................................................. 40-556
Failure code [DXH1KA] Lock-up ECMV:Open..................................................................... 40-558
Failure code [DXH1KB] Lock-up ECMV: Short circuit .......................................................... 40-560
Failure code [DXH1KY] Lock-up ECMV: Hot short .............................................................. 40-561
Failure code [DXH4KA] 1st clutch ECMV:Open .................................................................. 40-563
Failure code [DXH4KB] 1st clutch ECMV:Short circuit ......................................................... 40-564
Failure code [DXH4KY] 1st clutch ECMV:Hot short ............................................................. 40-565
Failure code [DXH5KA] 2nd clutch ECMV:Open ................................................................. 40-567
Failure code [DXH5KB] 2nd clutch ECMV:Short circuit ........................................................ 40-568
Failure code [DXH5KY] 2nd clutch ECMV:Hot short ............................................................ 40-569
Failure code [DXH6KA] 3rd clutch ECMV:Open .................................................................. 40-571
Failure code [DXH6KB] 3rd clutch ECMV:Short circuit......................................................... 40-572
Failure code [DXH6KY] 3rd clutch ECMV:Hot short ............................................................. 40-573
Failure code [DXH7KA] R clutch ECMV:Open .................................................................... 40-575
Failure code [DXH7KB] R clutch ECMV:Short circuit ........................................................... 40-576
Failure code [DXH7KY] R clutch ECMV:Hot short ............................................................... 40-577
Failure code [DXH8KA] F clutch ECMV:Open..................................................................... 40-579
Failure code [DXH8KB] F clutch ECMV:Short circuit............................................................ 40-580
Failure code [DXH8KY] F clutch ECMV:Hot short................................................................ 40-581
Failure code [DXJ4KA] Weq lock Sol.:Open ....................................................................... 40-583
Failure code [DXJ4KB] Weq lock Sol.:Short circuit .............................................................. 40-585
Failure code [DXJCKA] Blade angle left EPC:Open............................................................. 40-586
Failure code [DXJCKB] Blade angle left EPC:Short circuit ................................................... 40-587
Failure code [DXJCKY] Blade angle left EPC:Hot short ....................................................... 40-588
Failure code [DXJDKA] Blade angle right EPC:Open .......................................................... 40-590
Failure code [DXJDKB] Blade angle right EPC:Short circuit ................................................. 40-591
Failure code [DXJDKY] Blade angle right EPC:Hot short ..................................................... 40-592
Troubleshooting of electrical system (E-mode) .......................................................................... 40-594
E-1 Engine does not start (Engine does not crank) .............................................................. 40-594
E-2 Manual preheating does not work ................................................................................ 40-600
E-3 Automatic preheating does not work ............................................................................ 40-603
E-4 While preheating is working, preheating monitor does not light up .................................. 40-605
E-5 When starting switch is turned to ON position, machine monitor displays nothing............. 40-607
E-6 When starting switch is turned to ON position (with engine stopped), basic check monitor
lights up ............................................................................................................. 40-610
E-7 Air cleaner clogging monitor lights up in yellow while engine is running ........................... 40-611
E-8 Charge level monitor lights up while engine is running ................................................... 40-612
E-9 Engine coolant temperature monitor lights up while engine is running ............................. 40-614
E-10 Engine oil pressure monitor lights up while engine is running ....................................... 40-615
E-11 Power train oil temperature monitor lights up while engine is running ............................ 40-616
E-12 Hydraulic oil temperature monitor lights up while engine is running ............................... 40-617
E-13 Engine coolant temperature gauge does not indicate correct temparature ..................... 40-618
E-14 Fuel level gauge does not indicate correct level .......................................................... 40-619
E-15 Power train oil temperature gauge (multi-gauge) does not indicate correct
temperature ....................................................................................................... 40-621
E-16 Hydraulic oil temperature gauge (multi-gauge) does not indicate correct
temperature ....................................................................................................... 40-622
E-17 Operation mode does not change .............................................................................. 40-623
E-18 Gearshift mode does not change ............................................................................... 40-624
E-19 Operating customize switch does not display customize screen ................................... 40-625
E-20 Modifying setting on customize screen does not change setting of machine .................. 40-626
E-21 Reverse slow mode does not function properly ........................................................... 40-627
E-22 Alarm buzzer does not sound or does not stop sounding ............................................. 40-628
E-23 While starting switch is in OFF position, service meter is not displayed ......................... 40-629

D65EX,PX,WX-17 00-9
00 Index and foreword
Index

E-24 Service mode cannot be selected .............................................................................. 40-630

E-25 Horn does not sound ................................................................................................ 40-631
E-26 Horn does not stop sounding..................................................................................... 40-632
E-27 Backup alarm does not sound ................................................................................... 40-633
E-28 Backup alarm does not stop sounding........................................................................ 40-635
E-29 Headlamp does not light up....................................................................................... 40-636
E-30 Rear lamp does not light up....................................................................................... 40-639
E-31 No wiper operates continuously or intermittently.......................................................... 40-641
E-32 Front wiper does not operate (Failure in both continuous and intermittent
operations)......................................................................................................... 40-644
E-33 Rear wiper does not operate (Failure in both continuous and intermittent
operations)......................................................................................................... 40-647
E-34 Left door wiper does not operate (Failure of both continuous and intermittent
operations)......................................................................................................... 40-650
E-35 Right door wiper does not operate (Failure of both continuous and intermittent
operations)......................................................................................................... 40-653
E-36 KOMTRAX system does not operate properly............................................................. 40-656
Troubleshooting of hydraulic and mechanical system (H-mode) .................................................. 40-658
Information mentioned in troubleshooting table (H mode) .................................................... 40-658
System diagram of hydraulic and mechanical system.......................................................... 40-659
List of Failure Mode and Cause ......................................................................................... 40-661
H-1 Machine lacks power (insufficient drawbar pull) ............................................................ 40-664
H-2 Machine cannot travel (at 2nd or 3rd speed) ................................................................. 40-666
H-3 Machine does not start at all gear speeds..................................................................... 40-667
H-4 Machine travels only in one direction, either forward or in reverse .................................. 40-668
H-5 Large time lag at gear shifting or directional selection.................................................... 40-669
H-6 Machine cannot be steered (machine does not turn left or right) ..................................... 40-670
H-7 Steering speed or power is insufficient ......................................................................... 40-671
H-8 Brake does not operate .............................................................................................. 40-672
H-9 Torque converter does not lock up ............................................................................... 40-673
H-10 Power train oil overheats .......................................................................................... 40-674
H-11 Unusual noise is heard from around HSS and work equipment pump or HSS
motor ................................................................................................................. 40-675
H-12 All work equipment operates slowly ........................................................................... 40-676
H-13 All work equipment does not operate ......................................................................... 40-677
H-14 Blade lift speed or power is low ................................................................................. 40-678
H-15 Blade tilt speed or power is low ................................................................................. 40-679
H-16 Blade angle speed or power is low............................................................................. 40-680
H-17 Ripper lift speed or power is low ................................................................................ 40-681
H-18 Hydraulic drift of lifted blade is large........................................................................... 40-682
H-19 Hydraulic drift of tilted blade is large........................................................................... 40-683
H-20 Hydraulic drift of lifted ripper is large .......................................................................... 40-684
H-21 Fans speed is abnormal (high, low, or no rotation)....................................................... 40-685
H-22 Unusual noise is heard from around fan ..................................................................... 40-687
Troubleshooting of engine (S-mode)......................................................................................... 40-688
Information contained in troubleshooting table (S mode)...................................................... 40-688
S-1 When starting switch is turned to START position, engine is not cranked......................... 40-689
S-2 The engine cranks but exhaust smoke does not come out ............................................. 40-690
S-3 Fuel is being injected but engine does not start (incomplete combustion: engine cranks but
does not start) .................................................................................................... 40-691
S-4 Startability is poor....................................................................................................... 40-692
S-5 Engine does not pick up smoothly ............................................................................... 40-694
S-6 Engine stops during operation ..................................................................................... 40-696
S-7 Engine runs rough or is unstable ................................................................................. 40-698
S-8 Engine lacks power .................................................................................................... 40-699
S-9 Exhaust gas is black (KDPF gets clogged in a short time) .............................................. 40-701
S-10 Engine oil consumption is excessive .......................................................................... 40-703
S-11 Engine oil becomes contaminated early...................................................................... 40-704
S-12 Fuel consumption is excessive .................................................................................. 40-705

00-10 D65EX,PX,WX-17
 00 Index and foreword
Index

S-13 Oil is in coolant (or coolant spurts or coolant level goes down)...................................... 40-706
S-14 Oil pressure drops .................................................................................................... 40-707
S-15 Fuel mixes into engine oil.......................................................................................... 40-708
S-16 Water mixes into engine oil (milky) ............................................................................. 40-709
S-17 Coolant temperature rises too high (overheating) ........................................................ 40-710
S-18 Unusual noise is made ............................................................................................. 40-711
S-19 Vibration is excessive ............................................................................................... 40-712
S-20 Air cannot be bled from fuel circuit ............................................................................. 40-713
S-21 Frequent active regeneration..................................................................................... 40-714
S-22 Active regeneration is long ........................................................................................ 40-715
S-23 White smoke is exhausted during active regeneration ................................................. 40-716
50 Disassembly and assembly ........................................................................................................... 50-3
General information on disassembly and assembly........................................................................ 50-4
How to read this manual ....................................................................................................... 50-4
Coating materials list ............................................................................................................ 50-6
Special tool list................................................................................................................... 50-10
Sketches of special tools .................................................................................................... 50-20
Engine and cooling system ........................................................................................................ 50-35
Removal and installation of supply pump assembly............................................................... 50-35
Removal and installation of fuel injector assembly................................................................. 50-40
Removal and installation of cylinder head assembly.............................................................. 50-54
Removal and installation of radiator assembly ...................................................................... 50-72
Removal and installation of aftercooler and assembly ........................................................... 50-77
Removal and installation of hydraulic oil cooler assembly ...................................................... 50-80
Removal and installation of power train oil cooler assembly ................................................... 50-82
Removal and installation of cooling fan drive assembly ......................................................... 50-84
Removal and installation of cooling fan motor assembly ........................................................ 50-86
Removal and installation of engine assembly ....................................................................... 50-88
Removal and installation of damper assembly ...................................................................... 50-95
Removal and installation of engine front seal ........................................................................ 50-98
Removal and installation of engine rear seal....................................................................... 50-101
Removal and installation of engine hood assembly ............................................................. 50-109
Removal and installation of fuel tank assembly ....................................................................50-111
Removal and installation of KDPF assembly....................................................................... 50-113
Disassembly and assembly of KDPF ................................................................................. 50-117
Removal and installation of KCCV assembly ...................................................................... 50-125
Removal and installation of air cleaner assembly ................................................................ 50-129
Power train............................................................................................................................. 50-130
Removal and installation of power train unit assembly ......................................................... 50-130
Disconnecting and connecting of power train unit assembly ................................................. 50-135
Disassembly and assembly of PTO ................................................................................... 50-140
Disassembly and assembly of torque converter .................................................................. 50-144
Disassembly and assembly of TORQFLOW transmission.................................................... 50-153
Disassembly and assembly of HSS ................................................................................... 50-177
Removal and installation of final drive assembly ................................................................. 50-196
Disassembly and assembly of final drive ............................................................................ 50-198
Undercarriage and frame......................................................................................................... 50-211
Removal and installation of track frame assembly ............................................................... 50-211
Removal and installation of idler assembly ......................................................................... 50-213
Disassembly and assembly of idler .................................................................................... 50-215
Removal and installation of recoil spring assembly.............................................................. 50-219
Disassembly and assembly of recoil spring ........................................................................ 50-220
Removal and installation of track roller assembly ................................................................ 50-224
Disassembly and assembly of track roller ........................................................................... 50-225
Removal and installation of carrier roller assembly .............................................................. 50-228
Disassembly and assembly of carrier roller......................................................................... 50-229
Separation and connection of track shoe assembly (Standard type track shoe) ..................... 50-232
Separation and connection of track shoe assembly (PLUS type track shoe) .......................... 50-235
Overall disassembly and assembly of track shoe (standard type track shoe) ......................... 50-236

D65EX,PX,WX-17 00-11
00 Index and foreword
Index

Overall disassembly and assembly of track shoe (PLUS type track shoe) ............................. 50-249
Disassembly and assembly of one link in field (standard type track shoe).............................. 50-261
Disassembly and assembly of one link in field (PLUS type track shoe).................................. 50-268
Removal and installation of pivot shaft assembly ................................................................ 50-273
Removal and installation of equalizer bar assembly ............................................................ 50-274
Disassembly and assembly of equalizer bar side bushing.................................................... 50-276
Hydraulic system .................................................................................................................... 50-277
Removal and installation of hydraulic tank assembly ........................................................... 50-277
Removal and installation of control valve assembly ............................................................. 50-280
Disassembly and assembly of control valve........................................................................ 50-284
Disassembly and assembly of blade PPC valve.................................................................. 50-285
Disassembly and assembly of ripper PPC valve ................................................................. 50-286
Removal and installation of HSS pump and cooling fan pump assembly ............................... 50-287
Removal and installation of steering lubrication pump and power train pump
assembly ........................................................................................................... 50-289
Removal and installation of cooling scavenging pump assembly .......................................... 50-291
Removal and installation of HSS motor assembly ............................................................... 50-292
Disassembly and assembly of hydraulic cylinder................................................................. 50-294
Work equipment ..................................................................................................................... 50-300
Removal and installation of blade assembly (ST-TPP dozer)................................................ 50-300
Removal and installation of blade assembly (PAT dozer) ..................................................... 50-302
Removal and installation of ripper assembly ....................................................................... 50-304
Cab and its attachments .......................................................................................................... 50-307
Removal and installation of ROPS cab assembly................................................................ 50-307
Removal and installation of operator's cab glass (adhesion glass) ........................................ 50-313
Removal and installation of operator's sea.......................................................................... 50-318
Removal and installation of seat belt .................................................................................. 50-319
Removal and installation of air conditioner unit assembly..................................................... 50-320
Removal and installation of air conditioner compressor assembly......................................... 50-324
Electric system ....................................................................................................................... 50-325
Removal and installation of machine monitor assembly ....................................................... 50-325
Removal and installation of engine controller assembly ....................................................... 50-326
Removal and installation of power train controller assembly................................................. 50-327
Removal and installation of mass air flow and temperature sensor ....................................... 50-329
Removal and installation of KOMTRAX terminal ................................................................. 50-330
60 Maintenance standard................................................................................................................... 60-2
Engine and cooling system .......................................................................................................... 60-3
Engine mount ...................................................................................................................... 60-3
Damper ............................................................................................................................... 60-4
Cooling system .................................................................................................................... 60-6
Cooling fan pump ................................................................................................................. 60-7
Cooling fan motor............................................................................................................... 60-10
Power train............................................................................................................................... 60-12
Power train mount .............................................................................................................. 60-12
Universal joint .................................................................................................................... 60-14
Torque converter and PTO .................................................................................................. 60-15
Transmission ..................................................................................................................... 60-18
Transmission control valve.................................................................................................. 60-22
Forward-reverse clutch ECMV and gear shift clutch ECMV .................................................... 60-23
Lockup clutch ECMV .......................................................................................................... 60-24
Main relief valve and torque converter relief valve ................................................................. 60-25
Transmission lubricating oil relief valve ................................................................................ 60-26
Bevel gear shaft, HSS, and brake ........................................................................................ 60-27
Brake valve ....................................................................................................................... 60-32
Final drive ......................................................................................................................... 60-33
Sprocket............................................................................................................................ 60-36
Undercarriage and frame........................................................................................................... 60-40
Main frame ........................................................................................................................ 60-41
Suspension ....................................................................................................................... 60-43

00-12 D65EX,PX,WX-17
 00 Index and foreword
Index

Track frame and idler cushion ............................................................................................. 60-45

Idler .................................................................................................................................. 60-47
Track roller ........................................................................................................................ 60-49
Carrier roller ...................................................................................................................... 60-53
Track shoe ........................................................................................................................ 60-55
Hydraulic system ...................................................................................................................... 60-60
Hydraulic tank.................................................................................................................... 60-60
Scavenging pump .............................................................................................................. 60-61
Steering lubricating pump and power train pump................................................................... 60-62
HSS pump......................................................................................................................... 60-63
HSS motor ........................................................................................................................ 60-65
Control valve ..................................................................................................................... 60-67
Blade PPC valve ................................................................................................................ 60-74
Ripper PPC valve............................................................................................................... 60-76
Quick drop valve ................................................................................................................ 60-78
Work equipment lock solenoid valve .................................................................................... 60-80
Angle control EPC valve ..................................................................................................... 60-83
Work equipment ....................................................................................................................... 60-84
Work equipment................................................................................................................. 60-84
Cutting edge and end bit ..................................................................................................... 60-92
Ripper ............................................................................................................................... 60-94
Lift cylinder ........................................................................................................................ 60-95
Tilt cylinder ........................................................................................................................ 60-96
Pitch cylinder ..................................................................................................................... 60-97
Angle cylinder .................................................................................................................... 60-98
Ripper cylinder................................................................................................................... 60-99
Cab and its attachments .......................................................................................................... 60-100
Cab mount ...................................................................................................................... 60-100
80 Appendix...................................................................................................................................... 80-2
Air conditioner ............................................................................................................................ 80-3
Precautions for refrigerant..................................................................................................... 80-3
Air conditioner component .................................................................................................... 80-4
Configuration and function of refrigeration cycle...................................................................... 80-7
Outline of refrigeration cycle.................................................................................................. 80-8
Air conditioner unit ............................................................................................................. 80-10
Dual pressure switch .......................................................................................................... 80-16
Air conditioner controller ..................................................................................................... 80-17
Air conditioner compressor ................................................................................................. 80-18
Condenser ........................................................................................................................ 80-19
Receiver drier .................................................................................................................... 80-20
Sunlight sensor .................................................................................................................. 80-21
Outside air temperature sensor ........................................................................................... 80-22
Procedure for testing and troubleshooting ............................................................................ 80-23
Circuit diagram and arrangement of connector pins............................................................... 80-25
System diagram................................................................................................................. 80-27
Input and output signals of the air conditioner controller ......................................................... 80-28
Layout of air conditioner related parts and connectors ........................................................... 80-30
Testing air leakage (duct) .................................................................................................... 80-39
Testing with self-diagnosis function ...................................................................................... 80-42
How to enter the electrical system abnormality record screen in service mode of machine
monitor ................................................................................................................ 80-43
Testing vent (mode) changeover.......................................................................................... 80-45
Testing FRESH/RECIRC air changeover.............................................................................. 80-46
Testing sunlight sensor ....................................................................................................... 80-47
Testing (dual) pressure switch for refrigerant......................................................................... 80-48
Testing relays .................................................................................................................... 80-49
Troubleshooting chart 1 ...................................................................................................... 80-50
Troubleshooting chart 2 ...................................................................................................... 80-51
Information mentioned in troubleshooting table ..................................................................... 80-54

D65EX,PX,WX-17 00-13
00 Index and foreword
Index

Failure code list related to air conditioner.............................................................................. 80-55

Failure code [879AKA] A/C Inner sensor Open Circuit ........................................................... 80-56
Failure code [879AKB] A/C Inner sensor Short Circuit ........................................................... 80-57
Failure code [879BKA] A/C Outer sensor Open Circuit .......................................................... 80-58
Failure code [879BKB] A/C Outer sensor Short Circuit .......................................................... 80-60
Failure code [879CKA] Ventilating sensor Open Circuit ......................................................... 80-62
Failure code [879CKB] Ventilating sensor Short Circuit.......................................................... 80-63
Failure code [879DKZ] Sunlight sensor Open or Short Circuit ................................................ 80-64
Failure code [879EMC] Ventilating Damper Abnormality ........................................................ 80-66
Failure code [879FMC] Air Mix Damper Abnormality ............................................................. 80-67
Failure code [879GKX] Refrigerant Abnormality .................................................................... 80-68
A-1 Troubleshooting for power supply system (Air conditioner does not operate) ..................... 80-69
A-2 Troubleshooting for compressor system (Air is not cooled)............................................... 80-71
A-3 Troubleshooting for blower motor system (Air does not come out or air flow is
abnormal) ............................................................................................................ 80-74
A-4 Troubleshooting for FRESH/RECIRC air changeover ...................................................... 80-76
Troubleshooting with gauge pressure................................................................................... 80-78
Connection of service tool................................................................................................... 80-81
Precautions for disconnecting and connecting air conditioner piping ....................................... 80-82
Handling of compressor oil.................................................................................................. 80-84
90 Diagrams and drawings................................................................................................................. 90-2
Hydraulic circuit diagram ............................................................................................................. 90-3
Symbols in hydraulic circuit diagram ...................................................................................... 90-3
Power train hydraulic circuit diagram...................................................................................... 90-7
Hydraulic circuit diagram....................................................................................................... 90-9
Electric circuit diagram .............................................................................................................. 90-21
Symbols in electric circuit diagram ....................................................................................... 90-21
Electric circuit diagram........................................................................................................ 90-25
Electric circuit diagram for air conditioner unit ....................................................................... 90-51
Index.................................................................................................................................................................... 1

00-14 D65EX,PX,WX-17
 00 Index and foreword
Foreword, safety and general information

Foreword, safety and general information

Important safety notice
(Rev. 2011/02)
• Appropriate servicing and repair are extremely important to ensure safe operation of the machine. The
Shop Manual describes the effective and safe servicing and repair methods recommended by Komatsu.
Some of these methods require the use of special tools designed by Komatsu for the specific purpose.
• The symbol mark k is used for such matters that require special precautions during the work. The work
indicated with the warning mark should be performed according to the instructions with special attention to
the precautions. Should a hazardous situation occur or be anticipated during such work, be sure to keep
safe first and take every necessary measure.

General precautions wear welding gloves, apron, shielding goggles,

cap and other clothes suited for welding work.
k Inappropriate handling creates an extreme • Before starting work, warm up your body
danger. Read and understand what is thoroughly to start work under good condition.
described in the Operation and Maintenance • Avoid continuing work for long hours and take
Manual before operating the machine. In rests at proper intervals to keep your body in
addition read this manual carefully and good condition. Take rests in specified safe
understand its contents before starting work. places.
• Before performing any greasing or repairs, read Safety points
all the safety labels stuck to the machine. For 1 Good arrangement
the locations of the safety labels and detailed 2 Correct work clothes
explanation of precautions, see the Operation Following work standard
3
and Maintenance Manual.
4 Making and checking signals
• Locate a place in the repair workshop to keep
Prohibition of operation and handling by
tools and removed parts. Always keep the tools 5
unlicensed workers
and parts in their correct places. Always keep
6 Safety check before starting work
the work area clean and make sure that there is
Wearing protective goggles (for cleaning or
no dirt, water, or oil on the floor. Smoke only in 7 grinding work)
the areas provided for smoking. Never smoke
Wearing shielding goggles and protectors (for
while working. 8 welding work)
• When performing any work, always wear safety
shoes and helmet. Do not wear loose work 9 Good physical condition and preparation
clothes, or clothes with buttons missing. Precautions against work which you are not
10 used to or you are used to too much
1. Always wear the protective eyeglasses when
hitting parts with a hammer. Preparation work
2. Always wear the protective eyeglasses when • Before adding oil or making any repairs, park the
grinding parts with a grinder, etc. machine on a hard and level ground, and apply
• When performing any work with two or more the parking brake and chock the wheels or
workers, always agree on the operating tracks to prevent the machine from moving.
procedure before starting. Always inform your • Before starting work, lower the work equipment
fellow workers before starting any step of the (blade, ripper, bucket, etc.) to the ground. If this
work. During the work, hang UNDER REPAIR is not possible, insert the lock pin or use blocks
warning tag in the operator's compartment. to prevent the work equipment from falling. In
• Only qualified workers must perform the work addition, be sure to lock all the control levers
and operation which require license or and hang warning tag on them.
qualification. • When disassembling or assembling, support the
• Keep all tools in good condition. Learn the machine with blocks, jacks, or stands before
correct way to use them, and use the proper starting the work.
ones of them. Before starting work, thoroughly • Remove all mud and oil from the steps or other
check the tools, machine, forklift truck, service places used to get on and off the machine.
car, etc. Always use the handrails, ladders or steps when
• If welding repairs are needed, always have a getting on or off the machine. Never jump on or
trained and experienced welder perform the off the machine. When a scaffolding is not
work. When performing welding work, always

D65EX,PX,WX-17 00-15
00 Index and foreword
Foreword, safety and general information

provided, use steps or a step ladder to secure When installing hoses and wires, be sure that
your footing. they will not be damaged by contact with other
parts when the machine is operated.
Precautions during work • When installing high pressure hoses and tubes,
• For the machine equipped with a battery make sure that they are not twisted. Damaged
disconnect switch, before starting the work, hoses and tubes are dangerous, so be
check that the system operating lamp is turned extremely careful when installing hoses and
OFF, and then turn the battery disconnect switch tubes for high-pressure circuits. In addition,
to the OFF (Q) position and pull the switch key check that connections of them are correct.
out. For machines without a battery disconnect • When assembling or installing parts, always
switch, before starting the work, remove the tighten them to the specified torques. When
cables from the battery. Always remove the installing protective parts such as guards, or
cable from the negative (–) terminal first. parts which vibrate violently or rotate at high
• Before disconnecting or removing components speeds, be particularly careful to check that they
of the oil, water, or air circuits, first release the are installed correctly.
remaining pressure completely from the circuit. • When aligning two holes, never insert your
When removing the oil filter cap, a drain plug, or fingers or hand. Be careful not to get your
an oil pressure pickup plug, loosen it slowly to fingers caught in a hole.
prevent the oil from spurting out. • When measuring hydraulic pressure, check that
• The coolant and oil in the circuits are hot when the measuring tools are correctly installed.
the engine is shut down. Be careful not to get • Take care when removing or installing the tracks
scalded. Wait for the oil and coolant to cool of track-type machines. When removing the
before performing any work on the oil or water track, the track separates suddenly, so never let
circuits. anyone stand at either end of the track.
• Before starting work, shut down the engine. • If the engine is operated for a long time in a
When working on or around a rotating part, in place which is not ventilated well, you may suffer
particular, shut down the engine. When checking from gas poisoning. Accordingly, open the
the machine without stopping the engine windows and doors to ventilate well.
(measuring oil pressure, revolving speed,
temperature, etc.), take extreme care not to get Precautions for slinging work and making
rolled or caught in rotating parts or moving parts. signals
• When raising a heavy component (heavier than • Only one appointed worker must make signals
25 kg), use a hoist or crane. Before starting work, and co-workers must communicate with each
check that the slings (wire ropes, chains, and other frequently. The appointed signaler must
hooks) are free from damage. Always use slings make specified signals clearly at a place where
which have ample capacity and install them to he (she) is well seen from the operator's seat
proper places. Operate the hoist or crane slowly and where he (she) can see the working
to prevent the component from hitting any other condition easily. The signaler must always stand
part. Do not work with any part still raised by the in front of the load and guide the operator safely.
hoist or crane. 1. Do not stand under the load.
• When removing a cover which is under internal 2. Do not step on the load.
pressure or under reaction force of a spring, • Check the slings before starting sling work.
always leave two bolts in diagonal positions. • Keep putting on gloves during sling work. (Put
Loosen those two bolts gradually and alternately on leather gloves, if available.)
to release the pressure, and then remove the • Measure the weight of the load by the eye and
cover. check its center of gravity.
• When removing components, be careful not to • Use proper sling according to the weight of the
break or damage the electrical wiring. Damaged load and method of slinging. If too thick wire
wiring may cause electrical fires. ropes are used to sling a light load, the load may
• When removing piping, stop the fuel or oil from slip and fall.
spilling out. If any fuel or oil drips onto the floor, • Do not sling a load with one wire rope alone. If it
wipe it off immediately. Fuel or oil on the floor is slung by one wire rope, It may rotate and slip
can cause you to slip and can even cause fires. out of the rope. Install two or more wire ropes
• As a general rule, do not use gasoline to wash symmetrically.
parts. Do not use it to clean electrical parts, in
particular. k Slinging with one rope may cause turning of
• Be sure to assemble all parts again in their the load during hoisting, untwisting of the
original places. Replace any damaged parts and rope, or slipping of the rope from its original
parts which must not be reused with new parts.

00-16 D65EX,PX,WX-17
 00 Index and foreword
Foreword, safety and general information

winding position on the load, which can result

in a dangerous accident.
• Limit the hanging angle to 60 degrees, as a rule.
• Do not sling a heavy load (25 kg or more) with
ropes forming a wide hanging angle from the
hook.
a When hoisting a load with two or more ropes,
the force subjected to each rope will increase
with the hanging angle. The figure below
shows the variation of allowable load in kN
{kg} when hoisting is made with two ropes,
each of which is allowed to sling up to 9.8 kN
• Do not use twisted or kinked wire ropes.
{1,000 kg} vertically, at various hanging
• When lifting up a load, observe the following.
angles. When the two ropes sling a load
vertically, up to 19.6 kN {2,000 kg} of total 1. Wind in the crane slowly until wire ropes are
weight can be suspended. This weight is stretched. When settling the wire ropes with
reduced to 9.8 kN {1,000 kg} when the two the hand, do not grasp them but press them
ropes make a hanging angle of 120 degrees. from above. If you grasp them, your fingers
If the two ropes sling a 19.6 kN {2,000 kg} may be caught.
load at a lifting angle of 150 degrees, each 2. After the wire ropes are stretched, stop the
rope is subjected to a force as large as 39.2 crane and check the condition of the slung
kN {4,000 kg}. load, wire ropes, and pads.
3. If the load is unstable or the wire rope or
chains are twisted, lower the load and lift it
up again.
4. Do not lift up the load at an angle.
• When lowering a load, observe the following.
1. When lifting down a load, stop it temporarily
at 30 cm above the floor, and then lower it
slowly.
2. Check that the load is stable, and then
remove the sling.
3. Remove kinks and dirt from the wire ropes
and chains used for the sling work, and put
them in the specified place.
• When installing wire ropes to an angular load,
apply pads to protect the wire ropes. If the load Precautions for using mobile crane
is slippery, apply proper material to prevent the a Read the Operation and Maintenance Manual of
wire rope from slipping. the crane carefully in advance and operate the
• Use the specified eyebolts and fix wire ropes, crane safely.
chains, etc. to them with shackles, etc.
• Apply wire ropes to the middle portion of the Precautions for using overhead traveling crane
hook.
k When raising a heavy part (heavier than 25
a Slinging near the tip of the hook may cause kg), use a hoist, etc. . In disassembly and
the rope to slip off the hook during hoisting. assembly, the weight of a part heavier than
The hook has the maximum strength at the
middle part. 25 kg is indicated after the mark of 4 .

• Before starting work, inspect the wire ropes,

brake, clutch, controller, rails, over wind stop
device, ground fault circuit interrupter, crane
collision prevention device, and power
application warning lamp, and check safety.
• Observe the signals for sling work.
• Operate the hoist at a safe place.
• Check the direction indicator plates (north, south,
east, and west) and the directions of the control
buttons without fail.

D65EX,PX,WX-17 00-17
00 Index and foreword
Foreword, safety and general information

• Do not sling a load at an angle. Do not move the Precautions for disconnecting and connecting
crane while the slung load is swinging. hoses and tubes in air conditioner circuit
• Do not raise or lower a load while the crane is
Disconnection
moving longitudinally or laterally.
• Do not drag a sling. k Disconnection although the refrigerant
• When lifting up a load, stop it just after it leaves (refrigerant gas: R134a) used on the
the ground and check safety, and then lift it up. machine's air conditioner is less destructive
• Consider the travel route in advance and lift up a to the ozone layer for environmentally
load to a safe height. friendliness, it is not allowed to be released
• Place the control switch in a position where it will into the atmosphere as is. Whenever
not be an obstacle to work and passage. disconnecting the air conditioner gas circuit,
• After operating the hoist, do not swing the be sure to recover the refrigerant gas to
control switch. reuse it.
• Remember the position of the main switch so
that you can turn off the power immediately in an a Ask a qualified person for collection, and charge
emergency. of the refrigerant (R134a).
• If the hoist stops because of a power failure, turn a Never release the refrigerant (R134a) to the
the power switch OFF. When turning on a switch atmosphere.
which was turned OFF by the ground fault circuit
interrupter, check that the devices related to that k If refrigerant gas (R134a) gets in your eyes,
switch are not in operating condition. you may lose your sight. And if it touches
• If you find an obstacle around the hoist, stop the your skins, you may suffer from frostbite.
operation. Accordingly, put on protective eyeglasses,
• After finishing the work, stop the hoist at the gloves and working suits with long sleeves
specified position and raise the hook to at least while you are collecting or filling the
two meters above the floor. Do not leave the refrigerant (R134a).
sling attached to the hook.
• When loosening the nuts fixing air conditioner
Selecting wire ropes hoses and tubes, be sure to use two wrenches;
• Select adequate ropes depending on the weight use one wrench to fix and use the other one to
of parts to be hoisted, referring to the table loosen the nut.
below
Connection
Wire ropes (standard "Z" twist ropes without
• When installing the air conditioner hoses and
galvanizing) (JIS G3525, No. 6, Type 6x37-A)
tubes, take care to prevent any dirt, dust or
Nominal water from entering.
diameter of rope Allowable load
• When installing the air conditioner hoses and
mm kN ton tubes, check that O-rings are fitted to their joints.
10 8.8 0.9 • Once an O-ring is used, it is deformed and
12 12.7 1.3 deteriorated. Accordingly, do not reuse it.
14 17.3 1.7 • When removing O-rings, use a soft tool so that
16 22.6 2.3 the piping will not be damaged.
18 28.6 2.9 • Check that there is no defect or deterioration on
20 35.3 3.6 the O-ring.
• Apply compressor oil for refrigerant (R134a) to
25 55.3 5.6
the O-ring.
30 79.6 8.1
40 141.6 14.4 a However, do not apply oil to the threads
50 221.6 22.6 portion of a bolt, nut or union.
60 318.3 32.4 Manufacturer Part name
DENSO ND–OIL8
a The allowable load is one-sixth of the breaking
VALEO
strength of the rope to be used (Safety THERMAL ZXL100PG (equivalent to PAG46)
coefficient: 6). SYSTEMS
SANDEN SP–10
• When tightening nuts of the air conditioner
hoses and tubes, be sure to use two wrenches.
Use one wrench to fix and tighten the nut with

00-18 D65EX,PX,WX-17
Komatsu D65px 17 Shop Manual
Full download: http://manualplace.com/download/komatsu-d65px-17-shop-manual/
00 Index and foreword
Foreword, safety and general information

the other wrench to the specified torque (Use a

torque wrench for tightening).
a Example of fitting of O-ring
• An O-ring is fitted to every joint of hoses and
tubes in the air conditioner circuit.

a For tightening torques, see "Others",

"Precautions for disconnection and connection
of air conditioner piping".

D65EX,PX,WX-17 00-19

This is the cut pages sample. Download all 1848 page(s) at: ManualPlace.com